TopVent. Recirculation Units and Supply Air Units for Heating and Cooling High Spaces.

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1 TopVent. Recirculation Units and Supply Air Units for Heating and Cooling High Spaces.

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3 Safety A 3 TopVent DHV B Recirculation unit for heating high spaces 7 TopVent DKV C Recirculation unit for heating and cooling high spaces 27 TopVent NHV D Recirculation unit for heating high spaces with lower comfort requirements (e.g. high rack warehouses) 45 TopVent commercial CAU E Roof unit for ventilating, heating and cooling supermarkets 65 TopVent commercial CUM F Roof unit for heating and cooling supermarkets 83 TopVent MH G Supply air unit for ventilating and heating high spaces 101 TopVent MK H Supply air unit for ventilating, heating and cooling high spaces 121 TopVent HV I Recirculation unit heater for rooms with up to 6 m height 139 TopVent curtain J Air curtain 153 Options K 165 Control Systems L 177 Operation M 205

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5 Safety A 1 Symbols 5 2 Operating safety 5 3 Maintenance safety 5 4 Operating instruction advice 5

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7 A Safety 1 Symbols 3 Maintenance safety Caution This symbol applies to all safety notices that warn of hazard to life and limb. Observe these notices and be on the alert! At the same time the relevant laws and regulations on safety and accident prevention must be adhered to. Attention This marks instructions, regulations and working methods that are of particular importance to avoid damage to the unit. Note This identifies places where details of the economical use of the unit are given as well as special tips. 2 Operating safety TopVent units are built to the latest technology and are safe to operate. Nevertheless these units can be dangerous if inappropriately installed or put to improper use. Therefore: Read and carefully adhere to the operating instructions and the safety instructions for the units before unpacking, installing and servicing! Keep the operating instructions in an accessible place. The units are only to be installed, operated and serviced by authorised, trained specialists. Strictly observe all instructions and warning labels. The local safety and accident prevention regulations for installation and operation of the units are to be observed and adhered to! Maintenance and repairs are only to be carried out by authorised specialists or by customer service. The particular hazards, e.g., when working on electrical systems are to be heeded. Before starting maintenance and work to eliminate malfunctions disconnect the unit from the mains and protect it against reconnection with a lock. Before starting maintenance and work to eliminate malfunctions switch the isolation switch (if installed) to Off. Only the fan is switched off with the isolation switch. Options (e.g. the VarioTronic) can still be live! Beware of unprotected, sharp metal edges when working on the TopVent unit. Immediately renew any damaged or removed information and warning signs. Do not remove, paint over or paste anything on information and warning signs. After maintenance work properly reinstall all removed protective devices. Unauthorised revamping and modifying of the unit can have an adverse effect on the safety of individuals and units and should therefore not be done. Spare parts must comply with the technical requirements. Recommendation: Only use original Hoval spare parts. 4 Operating instruction advice According to the accident prevention regulations in certain countries the owner of the system must advise the operating personnel of all possible risks and preventive measures. This can be done with operating directions. Operating instructions are helpful in this case. In addition to emphasising important points, these instructions should contain local regulations for accident prevention and environmental protection. 5

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9 TopVent DHV B Recirculation unit for heating high spaces 1 Intended use 8 2 Function and construction 9 3 Technical data 10 4 Options 18 5 Control systems 19 6 System design 20 7 Transport and installation 22 8 Specification texts 24

10 TopVent DHV Intended Use 1 Intended use TopVent DHV are recirculation unit heaters for use in high spaces. Correct usage also entails adherence to the manufacturer's conditions for installation, initial start-up, operation and maintenance (operating instructions) as well as consideration of possible malfunctions and of hazards. 1.1 User group TopVent units are only to be installed, operated and serviced by authorised and trained specialists who are familiar with and have been instructed on the hazards. The operating instructions are for English-speaking works engineers and technicians as well as specialists in building, heating and ventilation technology. 1.2 Modes of operation TopVent DHV units have the following operating modes: Recirculation heating at low fan speed Recirculation heating at high fan speed Standby Off The application limits given in the 'Technical Data' section must be observed. Any utilisation beyond this is considered inappropriate. The manufacturer is not liable for any damages resulting therefrom. In standard design the units are not suitable for use in explosive atmospheres, in high humidity areas or in rooms with a high dust load. 1.3 Hazards Despite all of the preventive measures that have been taken, there are certain hazards, which may not be obvious, e.g.: Danger when working on the electrical system Items (e.g. tools) can drop down when work is being done on the TopVent unit Malfunctions due to defective parts Danger from hot water when working on the heating system 8

11 TopVent DHV Function and Construction B 2 Function and construction Heating section The TopVent DHV unit is used for recirculation heating; it has been specially developed for application in high spaces. The unit is installed under the ceiling. It takes in room air, heats it by means of the heater battery and injects it back into the room via the Air-Injector. Thanks to its powerful and efficient air distribution the TopVent DHV covers a large area. Therefore, in comparison with other systems, fewer units are needed to achieve the required environment. Three unit sizes, two-speed fans, different heater battery types and a wide variety of accessories provide a tailored solution for each application. Furthermore, special batteries (steam, electrical heating) are also available. 2.1 Unit construction The TopVent DHV consists of the heating section (with fan and heater battery) and the automatically adjustable vortex air distributor Air-Injector. These two components are bolted together and can be dismantled, even after installation. Air-Injector Fig. B2 1: TopVent DHV unit components 2.2 Air distribution with the Air-Injector The patented air distributor called the Air-Injector is the core element. Its controllable vane arrangement allows continuous adjustment of the air discharge angle. The setting depends on the air flow rate ( fan speed), the mounting height and the temperature difference between supply air and room air. Thus the air is injected into the room either vertically downwards, conically or horizontally, ensuring that a large floor area is reached with each TopVent DHV unit no draughts occur in the occupied area temperature stratification in the room is reduced and thus energy is saved. Casing: consisting of corrosion-resistant Aluzinc sheet steel Fan: axial fan with low energy consumption, quiet and maintenance-free Heat exchanger: LPHW heater battery consisting of copper tubes with aluminium fins Terminal box Sound attenuation cowl Air-Injector: patented, automatically adjustable vortex air distributor for draught-free air distribution over a large area Fig. B2 2: Construction of TopVent DHV 9

12 TopVent DHV Technical Data 3 Technical data Unit type Fan speed RPM (nominal) min -1 Nominal air flow rate m³ / h Floor area reached 1) max. m² Power consumption (at 400 V / 50 Hz) kw Current consumption (at 400 V / 50 Hz) A DHV-6 / A I DHV-6 / B I DHV-6 / C I Unit type Fan speed RPM (nominal) min -1 Nominal air flow rate m³ / h Floor area reached 1) max. m² Power consumption (at 400 V / 50 Hz) kw Current consumption (at 400 V / 50 Hz) A DHV-9 / A I DHV-9 / B I DHV-9 / C I Unit type Fan speed RPM (nominal) min -1 Nominal air flow rate m³ / h Floor area reached 1) max. m² Power consumption (at 400 V / 50 Hz) kw Current consumption (at 400 V / 50 Hz) A DHV-10 / A I DHV-10 / B I DHV-10 / C I ) Mounting height H max = 11 m up to 30 K temperature difference supply air - room air Table B3 1: Technical data of TopVent DHV Unit type reference Unit type TopVent DHV Unit size 6, 9 or 10 Heat exchanger Coil type A, B or C DHV 6 / A Unit type Fan speed Sound pressure level (5 m distance) 1) db(a) Total sound power level db(a) Octave sound power level 63 Hz db 125 Hz db 250 Hz db 500 Hz db 1000 Hz db 2000 Hz db 4000 Hz db 8000 Hz db DHV-6 I DHV-9 I DHV-10 I ) with hemispherical radiation in a room with little reflection Table B3 2: Unit type reference Table B3 3: Sound level of TopVent DHV 10

13 TopVent DHV Technical Data B DHV-6 Air inlet temperature LPHW Unit type C 90 / 70 DHV-6 / A I DHV-6 / B I DHV-6 / C I 80 / 60 DHV-6 / A I DHV-6 / B I DHV-6 / C I 10 C Q t S H max m W p W kw C m l / h kpa C Q t S H max m W p W kw C m l / h kpa C Q t S H max m W p W kw C m l / h kpa / 50 DHV-6 / A I DHV-6 / B I DHV-6 / C I / 40 DHV-6 / A I DHV-6 / B I DHV-6 / C I / 71 DHV-6 / A I DHV-6 / B I DHV-6 / C I Operating conditions not allowed because the maximum supply air temperature of 60 C is exceeded. Legend: Q = Heat output t S = Supply air temperature H max = Maximum mounting height m W = Water flow rate p W = Water pressure drop Table B3 4: Heat outputs of TopVent DHV-6 11

14 TopVent DHV Technical Data DHV-9 Air inlet temperature LPHW Unit type C 90 / 70 DHV-9 / A I DHV-9 / B I DHV-9 / C I 80 / 60 DHV-9 / A I DHV-9 / B I DHV-9 / C I 10 C Q t S H max m W p W kw C m l / h kpa C Q t S H max m W p W kw C m l / h kpa C Q t S H max m W p W kw C m l / h kpa / 50 DHV-9 / A I DHV-9 / B I DHV-9 / C I / 40 DHV-9 / A I DHV-9 / B I DHV-9 / C I / 71 DHV-9 / A I DHV-9 / B I DHV-9 / C I Operating conditions not allowed because the maximum supply air temperature of 60 C is exceeded. Legend: Q = Heat output t S = Supply air temperature H max = Maximum mounting height m W = Water flow rate p W = Water pressure drop Table B3 5: Heat outputs of TopVent DHV-9 12

15 TopVent DHV Technical Data B DHV-10 Air inlet temperature LPHW Unit type C 90 / 70 DHV-10 / A I DHV-10 / B I DHV-10 / C I 80 / 60 DHV-10 / A I DHV-10 / B I DHV-10 / C I 10 C Q t S H max m W p W kw C m l / h kpa C Q t S H max m W p W kw C m l / h kpa C Q t S H max m W p W kw C m l / h kpa / 50 DHV-10 / A I DHV-10 / B I DHV-10 / C I / 40 DHV-10 / A I DHV-10 / B I DHV-10 / C I / 71 DHV-10 / A I DHV-10 / B I DHV-10 / C I Operating conditions not allowed because the maximum supply air temperature of 60 C is exceeded. Legend: Q = Heat output t S = Supply air temperature H max = Maximum mounting height m W = Water flow rate p W = Water pressure drop Table B3 6: Heat outputs of TopVent DHV-10 13

16 TopVent DHV Technical Data 28 E 4 x M10 T G H B N F J C Return Flow R D A Unit type A mm B mm C mm T mm E mm F mm G mm H mm J " N mm R mm D mm Weight kg Water content Type of heater battery l DHV Rp 1¼ (female) A B C DHV Rp 1½ (female) A B C DHV Rp 1½ (female) A B C Table B3 7: Dimensions and weights of TopVent DHV Maximum operating pressure 800 kpa Maximum heating medium temperature 120 C Maximum supply air temperature 60 C Maximum ambient temperature 40 C Table B3 8: Application limits of TopVent DHV 14

17 TopVent DHV Technical Data B R Z W X Y Unit type Fan speed Unit height R m Wall distance W min. m max. m Unit distance X min. m (centre to centre) max. m Mounting height Y 1) min. m Ceiling distance Z min. m DHV-6 / A I DHV-6 / B I DHV-6 / C I Unit type Fan speed Unit height R m Wall distance W min. m max. m Unit distance X min. m (centre to centre) max. m Mounting height Y 1) min. m Ceiling distance Z min. m DHV-9 / A I DHV-9 / B I DHV-9 / C I Unit type Fan speed Unit height R m Wall distance W min. m max. m Unit distance X min. m (centre to centre) max. m Mounting height Y 1) min. m Ceiling distance Z min. m DHV-10 / A I DHV-10 / B I DHV-10 / C I ) With the option 'Air outlet box' the minimum mounting height is 1 m lower in each case (see part K 'Options'). Table B3 9: Minimum and maximum distances 15

18 TopVent DHV Technical Data Pressure drop increase in Pa DHV-6 / A DHV-6 / B DHV-6 / C DHV-6 / A DHV-6 / B DHV-6 / C Example: An additional pressure drop of 46 Pa at 6100 m³/h results in a new air flow rate of 5300 m³/h. speed speed speed speed I speed I speed I Air flow rate in m³ / h Diagram B3 1: Air flow rate for TopVent DHV-6 with additional pressure drop Pressure drop increase in Pa DHV-9 / A DHV-9 / B DHV-9 / C DHV-9 / A DHV-9 / B DHV-9 / C speed speed speed speed I speed I speed I Air flow rate in m³ / h Diagram B3 2: Air flow rate for TopVent DHV-9 with additional pressure drop 16

19 TopVent DHV Technical Data B 120 Pressure drop increase in Pa DHV-10 / A speed DHV-10 / B speed DHV-10 / C speed DHV-10 / A speed I DHV-10 / B speed I DHV-10 / C speed I Air flow rate in m³ / h Diagram B3 3: Air flow rate for TopVent DHV-10 with additional pressure drop 17

20 TopVent DHV Options 4 Options A wide range of accessories allows customisation of TopVent DHV units for each individual project. For a detailed description of all optional components please refer to part K 'Options' of this handbook. Paint finish Suspension set Isolation switch Actuator for Air-Injector Filter box Acoustic cowl Recirculation silencer Air outlet box Explosion-proof components In the Hoval standard colours red / orange (for free) or in any desired colour (extra charge) For fastening the unit to the ceiling External on / off mains switch For adjustment of the Air-Injectors when using a non-hoval control system (for Hoval control equipment see section 5 'Control systems') For filtering recirculated air For lowering the noise level in the room (reduced noise radiation from the Air-Injector) For lowering the noise level in the room (reduced noise reflection from the ceiling) For use on TopVent DHV units in low spaces (replaces the Air-Injector) For use of TopVent DHV units in explosive areas (zone 1 and zone 2), only for DHV-6 and DHV-9 Table B4 1: Options available with TopVent DHV 18

21 TopVent DHV Control Systems B 5 Control systems For TopVent DHV units, specially developed and optimised components for room temperature and air distribution control are available from Hoval. For a detailed description of these components please refer to part L 'Control systems' of this handbook. 5.1 Room temperature control TempTronic EasyTronic This is a programmable, electronic temperature controller allowing fully automatic operation. Its control algorithm with fuzzy logic ensures smallest room temperature deviations from setpoints and minimises energy consumption. This is a basic temperature controller without clock. The desired room temperature is manually adjusted and the fan speed selected with a switch. Table B5 1: Room temperature control systems for TopVent DHV 5.2 Air distribution control Automatic control with the VarioTronic The VarioTronic is an electronic controller for the Air-Injector. It adjusts air distribution for changing operating conditions (fan speed, temperature difference between supply air and room air) and works independently of room temperature control. Manual control by means of potentiometer and actuator Where operating conditions change rarely or comfort requirements are not so high, air distribution may be controlled manually by means of a potentiometer. Fixed adjustment Where the basic conditions remain unchanged (constant supply air temperature, constant air flow rate), air distribution can be manually fixed at commissioning. Table B5 2: Air distribution control systems for TopVent DHV For indoor climate systems where TopVent DHV units are combined with RoofVent fresh air units all control is by Hoval DigiNet. 19

22 TopVent DHV System Design 6 System design Example Collect basic data Space dimensions (floor plan) Mounting height (= distance from floor to underside of the TopVent unit) Required heat output Desired room temperature Heating medium temperature (flow / return) Comfort requirements (acoustic) Space dimensions...50 m x 70 m Mounting height...10 m Required heat output kw Desired room temperature...20 C Heating medium temperature / 60 C Comfort requirements...standard Comfort requirements (acoustic) According to acoustic requirements define the fan speed: Low sound level low fan speed (speed I) Normal sound level high fan speed (speed ) In this project the acoustic requirements are 'standard', hence use the high fan speed (speed ) for design calculations. Mounting height With the minimum mounting height (table B3-9) check which units can be used. Check maximum mounting height according to heating medium temperature and inlet air temperature (= room temperature) (tables B3-4, B3-5 and B3-6). Eliminate units that cannot be used. According to table B3-9 the minimum mounting heights are: DHV m DHV-9, DHV m Consequently, all sizes can be used in this project with a mounting height of 10 m. According to tables B3-4, B3-5 and B3-6 and the given conditions (heating medium temperature 80 / 60 C, inlet air temperature 20 C) the following unit types cannot be employed due to the maximum mounting height: DHV-6 / C... H max = 9.0 m DHV-9 / C... H max = 9.4 m Minimum and maximum number of units For determining the minimum number of units three criteria must be fulfilled: a) Minimum number relating to floor area Table B3-1 indicates the maximum floor area that can be reached with TopVent DHV units. With these values and the given floor area the minimum number of units can be determined for each unit size and coil type. b) Minimum number relating to space dimensions (length x width) Depending on space dimensions, a certain minimum number of units are required in the length and in the width. This can be calculated from the maximum distances between units and to the wall (see table B3-9). Calculate the minimum numbers according to a), b) and c) for each unit type and enter them in a table. Then take the highest value as minimum number of units d). Calculate the maximum possible number according to e) and enter the values in the table. 20

23 TopVent DHV System Design B c) Minimum number relating to heat output The minimum number for each unit size and coil type can be calculated from the required total heat output (tables B3-4, B3-5 and B3-6). d) Effective minimum number of units The highest value of the foregoing calculations a), b) and c) is the effective minimum number of units that should be installed. e) Maximum number of units The minimum number determined under d) normally corresponds to the solution selected in practice as it incurs the lowest costs. Yet if comfort requirements are particularly high more units may be provided. The maximum number of units is theoretically determined from the total floor area divided by the minimum floor area reached per unit X 2 (X = minimum distance between units, see table B3-9). Type a) b) c) d) e) DHV-6 / A DHV-6 / B DHV-6 / C no solution DHV-9 / A DHV-9 / B DHV-9 / C no solution DHV-10 / A DHV-10 / B DHV-10 / C Definite number of units According to space dimensions, comfort requirements and costs, select the optimum solution from the remaining alternatives. Due to the space dimensions, comfort requirements and the investment made available the solution with 6 TopVent DHV-9 / B is selected from the remaining variants. Automatic control Group units working under equal operating conditions (room temperature, heat demand, operating times) into control zones. Check maximum switching power of the controller. Check if, in view of operating conditions, automatic control of the air distributor with the VarioTronic is worthwhile. The low-cost solution is 1 TempTronic controller for all 6 units: Switching power = 6 x 0.98 kw < 6.5 kw The maximum floor area reached depends on the one hand on local conditions and on the other hand on the quality of air distribution. Due to the complexity of air flow mechanisms in large rooms the design quantities can only partly be mathematically described. The quality of the air distributor affects the supplied energy made available in the occupied area as a function of the air flow rate, the temperature difference between supply air and room air and the mounting height. Tests on the test rig and the experience of numerous applications show that with the Air-Injector this conversion of energy is effected with considerably higher efficiency than with other air distributors usually employed in recirculation units. This higher quality leads to lower running costs as well as to a larger floor area reached and thus fewer units are needed. To facilitate the design process concerning the floor area reached we have decided to dispense with complicated formulas and diagrams. However, it is important to keep to the limiting values and to make sure that the primary and secondary air flow can spread unhindered. If the given limits are exceeded in your application please seek Hoval advice. 21

24 TopVent DHV Transport and Installation 7 Transport and installation Transport and installation to be carried out by experts only! A lifting appliance is required for transportation and installation of the units! Do not tilt or lay the unit on its side! 7.1 Installation For fastening to the ceiling, the unit is equipped with four M10 captive nuts with hexagon head screws and washers as standard. With these and the height adjustable suspension set (option) the unit is easily fixed to the ceiling. The captive nuts are only designed for the unit's own weight. Do not put on any additional loads! The captive nuts cannot sustain a bending moment; therefore do not use eyebolts! Installation by means of steel flat, slotted steel flat, angle or steel wire is also possible, but the following has to be considered: 7.2 Hydraulic installation Hydraulic installation to be carried out by experts only! Combine units working under equal operating conditions (room temperature, heat gain, operating time, etc.) into one control zone. Low or medium pressure hot water up to 120 C can be used as a heating medium. To save energy, the distributor can be pre-calibrated; it should, however, be ensured that the heat requirement of each heater battery can always be met. Connect the individual heating coils as shown in figure B7 2. Depending on local conditions, it should also be considered whether compensations for flow and return pipework are needed to balance the longitudinal expansion and / or flexible connections for the units. The heat exchanger cannot take up any extra load, e.g. through the flow or return pipe. The individual units within a control zone must be hydraulically balanced to ensure even temperatures. Non-vertical suspensions are permissible up to a maximum angle of 45. The unit must be installed with its top face horizontal (level)! max. 45 max. 45 Air vent Balancing valve Drain cocks Isolating valves Flow Return Fig. B7 1: Suspension of TopVent DHV Fig. B7 2: Heating coil connection 22

25 TopVent DHV Transport and Installation B 7.3 Electrical installation The electrical connections to the unit must be carried out by an electrical expert. Relevant regulations must be observed. The unit is delivered ready for use. Check that the local operating voltage, frequency and fusing are in accordance with the information on the nameplate. If any discrepancies occur the unit must not be connected! Check cable diameters when using long wiring runs. Electrical installation to be carried out according to the wiring diagram for the control equipment. Connection of the TopVent units to be carried out according to the wiring diagram. Connect thermal relays built into the motor; otherwise the motor is not protected against overheating. Do not forget to install a main switch for the whole system (control, units). Several TopVent units can be connected in parallel. Thermal relays and isolation switches must be wired in series! Isolation switch (optional) Low fan speed (Y connection) Fan (wiring by the installer) Filter pressure switch (optional) Thermal relay High fan speed ( connection) (wiring by the installer) Fig. B7 3: Wiring diagram for TopVent DHV 23

26 TopVent DHV Specification texts 8 Specification texts TopVent DHV Recirculation unit for heating high spaces Casing made of corrosion-resistant Aluzinc sheet steel. For fastening to the ceiling, the unit is equipped with four M10 captive nuts with hexagon head screws and washers as standard. Heat exchanger of copper tubes with aluminium fins. Headers are made of steel. Fan unit consisting of a 2-speed three-phase motor of the external-rotor type with rigid sickle-shaped aluminium blade impeller, maintenance-free and quiet at high efficiency. Motor protection with built-in thermal relays. Protection rating IP54. Terminal box built into the casing sidewall for connection of mains supply and accessories. Vortex air distributor with concentric outlet nozzle, twelve adjustable guide vanes and integrated sound attenuation cowl. Actuator for Air-Injector VT-A Complete with cable, for adjustment of the Air-Injector when using a non-hoval control system. Filter box FK With two bag filters class G4 (to DIN EN 779). Filter pressure switch FUDHV For supervision of filter cleaning intervals. Acoustic cowl AHD Consisting of a sound attenuation cowl with bigger volume and a faceplate with sound-insulation lining, insertion attenuation 4 db(a). Recirculation silencer USD Fitted on top of the unit, made of Aluzinc sheet steel with sound-insulation inlay, insertion attenuation 3 db(a). Air outlet box AK Consisting of Aluzinc sheet steel with four adjustable horizontal grilles (replaces the Air-Injector). Technical data Fan speed I Nominal air flow rate m³ / h Floor area reached m² Mounting height m Nominal heating capacity kw with LPHW C and air inlet temperature C Power consumption kw Current consumption A Voltage 400 V / 50 Hz DHV-6 / A DHV-6 / B DHV-6 / C DHV-9 / A DHV-9 / B DHV-9 / C DHV-10 / A DHV-10 / B DHV-10 / C Standard paint finish SL In the Hoval colours red (RAL 3000) and orange (RAL 2008). Special paint finish AL In RAL colour No. Suspension set AHS For fastening the units to the ceiling, consisting of 4 pairs of Aluzinc steel U sections, height adjustable up to 1300 mm. Paint finish as for the unit. Isolation switch RS In the terminal box of the TopVent unit. 24

27 TopVent DHV Specification texts B TopVent DHV EEx Recirculation unit with explosion-proof components for heating high spaces Casing made of corrosion-resistant Aluzinc sheet steel. For fastening to the ceiling, the unit is equipped with four M10 captive nuts with hexagon head screws and washers as standard. Incl. measures avoiding electrostatic charge. Heat exchanger of copper tubes with aluminium fins. Headers are made of steel. Fan unit consisting of a 1-speed radial fan in explosionproof design. Motor protection with built-in PTC resistor. Protection rating IP44. Terminal box built into the casing sidewall for connection of mains supply and accessories. Vortex air distributor with concentric outlet nozzle, twelve adjustable guide vanes and integrated sound attenuation cowl. Technical data Nominal air flow rate m³ / h Floor area reached m² Mounting height m Nominal heating capacity kw with LPHW C and air inlet temperature C Power consumption kw Current consumption A Voltage 400 V / 50 Hz DHV-6 / A EEx DHV-6 / B EEx DHV-6 / C EEx DHV-9 / A EEx DHV-9 / B EEx DHV-9 / C EEx Standard paint finish SL In the Hoval colours red (RAL 3000) and orange (RAL 2008). Special paint finish AL In RAL colour No. Suspension set AHS For fastening the units to the ceiling, consisting of 4 pairs of Aluzinc steel U sections, height adjustable up to 1300 mm. Paint finish as for the unit. Room temperature control with the TempTronic Electronic controller with 2-speed 2-point control, fuzzy logic, clock with automatic summer / winter changeover and holiday programme. TempTronic SH, controller for heating operation, built as wall unit in a plastic casing with transparent lid, room air sensor included TempTronic SH-S, controller for heating operation, built for installation in a control panel (without casing, transformer, contactors and fuses), room air sensor included Three additional room air sensors for averaging TS1M Cylinder lock ZS for TempTronic wall unit Room temperature control with the EasyTronic Basic controller with 2-point control and manual fan speed switching. EasyTronic ET, controller for heating operation, built as wall unit in a plastic casing with transparent lid, room thermostat included Automatic air distribution control with the VarioTronic Electronic controller with well-proven control algorithm for changing operating conditions. VarioTronic VT-W, control module built as wall unit, in a plastic casing with transparent lid VarioTronic VT-S, control module for installation in a control panel (without casing, transformer, contactor and fuses) Cylinder lock ZS for VarioTronic wall unit Actuator VT-AK with cable, plug, supply air sensor and room air sensor Actuator VT-AS with cable and plug Separate room air sensor TS1 Manual air distribution control with the potentiometer Manual control by means of a potentiometer and actuator with a range of 0 to 50 for adjustment of the air discharge angle between vertical and horizontal. Potentiometer wall unit PMS-W Potentiometer for installation in a control panel PMS-S Actuator VT-AS with cable and plug Transformer TA for maximum 7 actuators Filter box FK EEx In explosion-proof design, with two bag filters class G4 (to DIN EN 779). Filter pressure switch FUDHV For supervision of filter cleaning intervals (intrinsically safe circuit by the installer). 25

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29 TopVent DKV C Recirculation unit for heating and cooling high spaces 1 Intended use 28 2 Function and construction 29 3 Technical data 30 4 Options 37 5 Control systems 38 6 System design 39 7 Transport and installation 41 8 Specification texts 43

30 TopVent DKV Intended Use 1 Intended use TopVent DKV are recirculation unit heaters and coolers for use in high spaces. Correct usage also entails adherence to the manufacturer's conditions for installation, initial start-up, operation and maintenance (operating instructions) as well as consideration of possible malfunctions and of hazards. 1.1 User group TopVent units are only to be installed, operated and serviced by authorised and trained specialists who are familiar with and have been instructed on the hazards. The operating instructions are for English-speaking works engineers and technicians as well as specialists in building, heating and ventilation technology. 1.2 Modes of operation TopVent DKV units have the following operating modes: Recirculation heating / cooling at low fan speed Recirculation heating / cooling at high fan speed Standby Off The application limits given in the 'Technical Data' section must be observed. Any utilisation beyond this is considered inappropriate. The manufacturer is not liable for any damages resulting therefrom. The units are not suitable for use in explosive atmospheres, in high humidity areas or in rooms with a high dust load. 1.3 Hazards Despite all of the preventive measures that have been taken, there are certain hazards, which may not be obvious, e.g.: Danger when working on the electrical system Items (e.g. tools) can drop down when work is being done on the TopVent unit Malfunctions due to defective parts Danger from hot water when working on the heating system 28

31 TopVent DKV Function and Construction C 2 Function and construction The TopVent DKV is used for recirculation heating and cooling; it has been specially developed for application in high spaces. The unit is installed under the ceiling. It takes in room air, heats or cools it and injects it back into the room via the Air-Injector. Thanks to its powerful and efficient air distribution the TopVent DKV covers a large area. Therefore, in comparison with other systems, fewer units are needed to achieve the required environment. Two unit sizes, two-speed fans, different coil types and a wide variety of accessories provide a tailored solution for each application. 2.1 Unit construction The TopVent DKV consists of the heating / cooling section (with fan, heat exchanger and built-in condensate separator) and the automatically adjustable vortex air distributor Air-Injector. To avoid condensation on the outer surface the heating / cooling section is insulated. The components are bolted together and can be dismantled, even after installation. Heating / cooling section Air-Injector Fig. C2 1: TopVent DKV unit components 2.2 Air distribution with the Air-Injector The patented air distributor called the Air-Injector is the core element. Its controllable vane arrangement allows continuous adjustment of the air discharge angle. The setting depends on the air flow rate ( fan speed), the mounting height and the temperature difference between supply air and room air. Thus the air is injected into the room either vertically downwards, conically or horizontally, ensuring that a large floor area is reached with each TopVent DKV unit no draughts occur in the occupied area temperature stratification in the room is reduced and thus energy is saved. Casing: consisting of corrosion-resistant Aluzinc sheet steel; the heating / cooling section is insulated Fan: axial fan with low energy consumption, quiet and maintenance-free Heat exchanger: LPHW / chilled water coil consisting of copper tubes with aluminium fins Condensate separator: with condensate drain connection Terminal box Sound attenuation cowl Air-Injector: patented, automatically adjustable vortex air distributor for draught-free air distribution over a large area Fig. C2 2: Construction of TopVent DKV 29

32 TopVent DKV Technical Data 3 Technical data Unit type Fan speed RPM (nominal) min -1 Nominal air flow rate m³ / h Floor area reached 1) max. m² Power consumption (at 400 V / 50 Hz) kw Current consumption (at 400 V / 50 Hz) A DKV-6 / C I DKV-9 / C I DKV-9 / D I ) Mounting height H max = 11 m up to 30 K temperature difference supply air - room air Table C3 1: Technical data of TopVent DKV Unit type reference Unit type TopVent DKV Unit size 6 or 9 Heat exchanger Coil type C or D DKV 6 / C Unit type Fan speed Sound pressure level (5 m distance) 1) Total sound power level Octave sound power level db(a) db(a) 63 Hz db 125 Hz db 250 Hz db 500 Hz db 1000 Hz db 2000 Hz db 4000 Hz db 8000 Hz db DKV-6 I DKV-9 I ) with hemispherical radiation in a room with little reflection Table C3 2: Unit type reference Table C3 3: Sound level of TopVent DHV 30

33 TopVent DKV Technical Data C Air inlet temperature LPHW Unit type C 10 C Q t S H max m W p W kw C m l / h kpa 15 C Q t S H max m W p W kw C m l / h kpa 20 C Q t S H max m W p W kw C m l / h kpa 90 / 70 DKV-6 / C I DKV-9 / C I DKV-9 / D I / 60 DKV-6 / C I DKV-9 / C I DKV-9 / D I / 50 DKV-6 / C I DKV-9 / C I DKV-9 / D I / 40 DKV-6 / C I DKV-9 / C I DKV-9 / D I / 71 DKV-6 / C I DKV-9 / C I DKV-9 / D I Operating conditions not allowed because the maximum supply air temperature of 60 C is exceeded. Legend: Q = Heat output t S = Supply air temperature H max = Maximum mounting height m W = Water flow rate p W = Water pressure drop Table C3 4: Heat outputs of TopVent DKV 31

34 TopVent DKV Technical Data DKV-6 Cooling medium temp. t ai rh Unit type C % DKV-6 / C I 50 DKV-6 / C I 70 DKV-6 / C I DKV-6 / C I 50 DKV-6 / C I 70 DKV-6 / C I 6 / 12 C Q tot Q sen t S m C m W p W 8 / 14 C Q tot Q sen t S m C m W p W 10 / 16 C Q tot Q sen t S m C m W p W kw kw C kg / h l / h kpa kw kw C kg / h l / h kpa kw kw C kg / h l / h kpa DKV-6 / C I 50 DKV-6 / C I 70 DKV-6 / C I Legend: t ai = Air inlet temperature rh = Air inlet humidity Q tot = Total cooling capacity Q sen = Sensible cooling capacity t S m C m W = Supply air temperature = Amount of condensate = Water flow rate p W = Water pressure drop Table C3 5: Cooling capacity of TopVent DKV-6 32

35 TopVent DKV Technical Data C DKV-9 Cooling medium temp. t ai rh Unit type C % DKV-9 / C I 50 DKV-9 / C I 70 DKV-9 / C I DKV-9 / C I 50 DKV-9 / C I 70 DKV-9 / C I 6 / 12 C Q tot Q sen t S m C m W p W 8 / 14 C Q tot Q sen t S m C m W p W 10 / 16 C Q tot Q sen t S m C m W p W kw kw C kg / h l / h kpa kw kw C kg / h l / h kpa kw kw C kg / h l / h kpa DKV-9 / C I 50 DKV-9 / C I 70 DKV-9 / C I DKV-9 / D I 50 DKV-9 / D I 70 DKV-9 / D I DKV-9 / D I 50 DKV-9 / D I 70 DKV-9 / D I DKV-9 / D I 50 DKV-9 / D I 70 DKV-9 / D I Legend: t ai = Air inlet temperature rh = Air inlet humidity Q tot = Total cooling capacity Q sen = Sensible cooling capacity t S m C m W = Supply air temperature = Amount of condensate = Water flow rate p W = Water pressure drop Table C3 6: Cooling capacity of TopVent DKV-9 33

36 TopVent DKV Technical Data 27 E 4x M10 N F T H G J B Inspection port C K Return Flow L M Condensate drain R D A Unit type A mm B mm C mm T mm E mm F mm G mm H mm J " K mm L mm M " N mm R mm D mm Weight kg Water content of coil l DKV-6 / C Rp 1¼ (female) Rp ¾ (female) DKV-9 / C Rp 1½ (female) Rp ¾ (female) DKV-9 / D Rp 2 (female) Rp ¾ (female) Table C3 7: Dimensions and weights of TopVent DKV 34

37 TopVent DKV Technical Data C Maximum operating pressure 800 kpa Maximum heating medium temperature 120 C Maximum supply air temperature 60 C Maximum ambient temperature 40 C Maximum amount of condensate DKV-6 Maximum amount of condensate DKV-9 Minimum air flow rate DKV-6 Minimum air flow rate DKV-9 40 kg 90 kg 3100 m³ / h 5000 m³ / h Table C3 8: Application limits of TopVent DKV R Z W X Y Unit type Fan speed Unit height R m Wall distance W min. m max. m Unit distance X min. m (centre to centre) max. m Mounting height Y 1) min. m Ceiling distance Z min. m DKV-6 / C I DKV-9 / C I DKV-9 / D I ) With the option 'Air outlet box' the minimum mounting height is 1 m lower in each case (see part K 'Options'). Table C3 9: Minimum and maximum distances 35

38 TopVent DKV Technical Data DKV-6 / C DKV-6 / C speed speed I Pressure drop increase in Pa Example: An additional pressure drop of 45 Pa at 4920 m³/h results in a new air flow rate of 4300 m³/h Air flow rate in m³ / h Diagram C3 1: Air flow rate for TopVent DKV-6 with additional pressure drop DKV-9 / C DKV-9 / D DKV-9 / C DKV-9 / D speed speed speed I speed I Pressure drop increase in Pa Air flow rate in m³ / h Diagram C3 2: Air flow rate for TopVent DKV-9 with additional pressure drop 36

39 TopVent DKV Options C 4 Options A wide range of accessories allows customisation of TopVent DKV units for each individual project. For a detailed description of all optional components please refer to part K 'Options' of this handbook. Paint finish Suspension set Isolation switch Actuator for Air-Injector Filter box Acoustic cowl Recirculation silencer Air outlet box Insulation Condensate pump In the Hoval standard colours red / orange (for free) or in any desired colour (extra charge) For fastening the unit to the ceiling External on / off mains switch For adjustment of the Air-Injectors when using a non-hoval control system (for Hoval control equipment see section 5 'Control systems') For filtering recirculated air For lowering the noise level in the room (reduced noise radiation from the Air-Injector) For lowering the noise level in the room (reduced noise reflection from the ceiling) For use on TopVent DKV units in low spaces (replaces the Air-Injector) Prevents condensation forming on the outer surfaces of the Air-Injector For condensate drainage through waste water pipes under the ceiling or onto the roof Table C4 1: Options available with TopVent DKV 37

40 TopVent DKV Control Systems 5 Control systems For TopVent DKV units, specially developed and optimised components for room temperature and air distribution control are available from Hoval. For a detailed description of these components please refer to part L 'Control systems' of this handbook. 5.1 Room temperature control TempTronic This is a programmable, electronic temperature controller allowing fully automatic operation. Its control algorithm with fuzzy logic ensures smallest room temperature deviations from setpoints and minimises energy consumption. Table C5 1: Room temperature control systems for TopVent DKV 5.2 Air distribution control Automatic control with the VarioTronic The VarioTronic is an electronic controller for the Air-Injector. It adjusts air distribution for changing operating conditions (fan speed, temperature difference between supply air and room air) and works independently of room temperature control. Manual control by means of potentiometer and actuator Where operating conditions change rarely or comfort requirements are not so high, air distribution may be controlled manually by means of a potentiometer. Fixed adjustment Where the basic conditions remain unchanged (constant supply air temperature, constant air flow rate), air distribution can be manually fixed at commissioning. Table C5 2: Air distribution control systems for TopVent DKV For indoor climate systems where TopVent DKV units are combined with RoofVent fresh air units all control is by Hoval DigiNet. 38

41 TopVent DKV System Design C 6 System design Example Usually, the primary function of TopVent DKV units is cooling; for this reason the design process is described for this function. The design for heating can be made in a similar way to the example in part B 'TopVent DHV'. Collect basic data Space dimensions (floor plan) Mounting height (= distance from floor to underside of the TopVent unit) Required cooling capacity Desired room conditions Cooling medium temperature (flow / return) Comfort requirements (acoustic) Space dimensions...55 m x 86 m Mounting height...8 m Required cooling capacity kw Desired room conditions...26 C / 50 % Cooling medium temperature... 8 / 14 C Comfort requirements...standard Comfort requirements (acoustic) According to acoustic requirements define the fan speed: Low sound level low fan speed (speed I) Normal sound level high fan speed (speed ) In this project the acoustic requirements are 'standard', hence use the high fan speed (speed ) for design calculations. Mounting height With the minimum mounting height (table C3-9) check which units can be used. According to table C3-9 the minimum mounting heights are: DKV m DKV m Consequently, all sizes can be used in this project with a mounting height of 8 m. Minimum and maximum number of units For determining the minimum number of units three criteria must be fulfilled: a) Minimum number relating to floor area Table C3-1 indicates the maximum floor area that can be reached with TopVent DKV units. With these values and the given floor area the minimum number of units can be determined for each unit size and coil type. b) Minimum number relating to space dimensions (length x width) Depending on space dimensions, a certain minimum number of units are required in the length and in the width. This can be calculated from the maximum distances between units and to the wall (see table C3-9. Calculate the minimum numbers according to a), b) and c) for each unit type and enter them in a table. Then take the highest value as minimum number of units d). Calculate the maximum possible number according to e) and enter the values in the table. 39

42 TopVent DKV System Design c) Minimum number relating to cooling capacity The minimum number for each unit size and coil type can be calculated from the required total cooling capacity (tables C3-5 and C3-6). Please note that only the sensible cooling capacity Q sen is available for cooling of the space while the total capacity Q tot must be used for sizing the chiller. Type a) b) c) d) e) DKV-6 / C DKV-9 / C DKV-9 / D d) Effective minimum number of units The highest value of the foregoing calculations a), b) and c) is the effective minimum number of units that should be installed. e) Maximum number of units The minimum number determined under d) normally corresponds to the solution selected in practice as it incurs the lowest costs. Yet if comfort requirements are particularly high more units may be provided. The maximum number of units is theoretically determined from the total floor area divided by the minimum floor area reached per unit X 2 (X = minimum distance between units, see table C3-9). Definite number of units According to space dimensions, comfort requirements and costs, select the optimum solution from the remaining alternatives. Due to the space dimensions, comfort requirements and the investment made available the solution with 7 TopVent DKV-9 / D is selected from the remaining variants. Automatic control Group units working under equal operating conditions (room temperature, cooling load, operating times) into control zones. Check maximum switching power of the controller. Check if, in view of operating conditions, automatic control of the air distributor with the VarioTronic is worthwhile. The low-cost solution is 3 TempTronic controllers: Switching power = 3 x 1.65 kw < 6.5 kw 2 x 1.65 kw < 6.5 kw 2 x 1.65 kw < 6.5 kw The maximum floor area reached depends on the one hand on local conditions and on the other hand on the quality of air distribution. Due to the complexity of air flow mechanisms in large rooms the design quantities can only partly be mathematically described. The quality of the air distributor affects the supplied energy made available in the occupied area as a function of the air flow rate, the temperature difference between supply air and room air and the mounting height. Tests on the test rig and the experience of numerous applications show that with the Air-Injector this conversion of energy is effected with considerably higher efficiency than with other air distributors usually employed in recirculation units. This higher quality leads to lower running costs as well as to a larger floor area reached and thus fewer units are needed. To facilitate the design process concerning the floor area reached we have decided to dispense with complicated formulas and diagrams. However, it is important to keep to the limiting values and to make sure that the primary and secondary air flow can spread unhindered. If the given limits are exceeded in your application please seek Hoval advice. 40

43 TopVent DKV Transport and Installation C 7 Transport and installation Transport and installation to be carried out by experts only! A lifting appliance is required for transportation and installation of the units! Do not tilt or lay the unit on its side! 7.1 Installation For fastening to the ceiling, the unit is equipped with four M10 captive nuts with hexagon head screws and washers as standard. With these and the height adjustable suspension set (option) the unit is easily fixed to the ceiling. The captive nuts are only designed for the unit's own weight. Do not put on any additional loads! The captive nuts cannot sustain a bending moment; therefore do not use eyebolts! Installation by means of steel flat, slotted steel flat, angle or steel wire is also possible, but the following has to be considered: 7.2 Hydraulic installation Hydraulic installation to be carried out by experts only! Combine units working under equal operating conditions (room temperature, heat gain, operating time, etc.) into one control zone. Low or medium pressure hot water up to 120 C can be used as a heating medium. To save energy, the distributor can be pre-calibrated; it should, however, be ensured that the heat requirement of each heater battery can always be met. Connect the individual heating / cooling coils as shown in figure C7 2. Depending on local conditions, it should also be considered whether compensations for flow and return pipework are needed to balance the longitudinal expansion and / or flexible connections for the units. The heat exchanger cannot take up any extra load, e.g. through the flow or return pipe. Adequately size the slope and cross section of the condensate drain to prevent a condensate backwash. Install a 200 mm trap. The individual units within a control zone must be hydraulically balanced to ensure even temperatures. Non-vertical suspensions are permissible up to a maximum angle of 45. The unit must be installed with its top face horizontal (level)! max. 45 max. 45 Air vent Balancing valve Drain cocks Isolating valves Flow Return Condensate drain (with trap) 2-port valve Fig. C7 1: Suspension of TopVent DKV Fig. C7 2: Heating / cooling coil connection 41

44 TopVent DKV Transport and Installation 7.3 Electrical installation The electrical connections to the unit must be carried out by an electrical expert. Relevant regulations must be observed. The unit is delivered ready for use. Check that the local operating voltage, frequency and fusing are in accordance with the information on the nameplate. If any discrepancies occur the unit must not be connected! Check cable diameters when using long wiring runs. Electrical installation to be carried out according to the wiring diagram for the control equipment. Connection of the TopVent units to be carried out according to the wiring diagram. Connect thermal relays built into the motor; otherwise the motor is not protected against overheating. Do not forget to install a main switch for the whole system (control, units). Several TopVent units can be connected in parallel. Thermal relays and isolation switches must be wired in series! The condensate separator only works with the fan running. Therefore, switch off the cooling pump together with the fan. Isolation switch (optional) Low fan speed (Y connection) Fan (wiring by the installer) Filter pressure switch (optional) Thermal relay High fan speed ( connection) (wiring by the installer) Fig. C7 3: Wiring diagram for TopVent DKV 42

45 TopVent DKV Specification texts C 8 Specification texts TopVent DKV Recirculation unit for heating and cooling high spaces Casing made of corrosion-resistant Aluzinc sheet steel, heating / cooling section insulated inside. For fastening to the ceiling, the unit is equipped with four M10 captive nuts with hexagon head screws and washers as standard. Heat exchanger of copper tubes with aluminium fins. Headers are made of steel. A condensate separator with drain connection is installed. Fan unit consisting of a 2-speed three-phase motor of the external-rotor type with rigid sickle-shaped aluminium blade impeller, maintenance-free and quiet at high efficiency. Motor protection with built-in thermal relays. Protection rating IP54. Terminal box built into the casing sidewall for connection of mains supply and accessories. Vortex air distributor with concentric outlet nozzle, twelve adjustable guide vanes and integrated sound attenuation cowl. Technical data Fan speed I Nominal air flow rate m³ / h Floor area reached m² Mounting height m Nominal cooling capacity kw with chilled water C air inlet temperature C and air inlet humidity % Nominal heating capacity kw with LPHW C and air inlet temperature C Power consumption kw Current consumption A Voltage 400 V / 50 Hz Suspension set AHS For fastening the units to the ceiling, consisting of 4 pairs of Aluzinc steel U sections, height adjustable up to 1300 mm. Paint finish as for the unit. Isolation switch RS In the terminal box of the TopVent unit. Actuator for Air-Injector VT-A Complete with cable, for adjustment of the Air-Injector when using a non-hoval control system. Filter box FK With two bag filters class G4 (to DIN EN 779). Filter pressure switch FUDHV For supervision of filter cleaning intervals. Acoustic cowl AHD Consisting of a sound attenuation cowl with bigger volume and a faceplate with sound-insulation lining, insertion attenuation 4 db(a). Recirculation silencer USD Fitted on top of the unit, made of Aluzinc sheet steel with sound-insulation inlay, insertion attenuation 3 db(a). Air outlet box AK Consisting of Aluzinc sheet steel with four adjustable horizontal grilles (replaces the Air-Injector). Insulation ID Of the Air-Injector. Condensate pump KP Consisting of a centrifugal pump, collecting tray and flexible hose, delivery output max. 80 l / h at 3 m delivery height. DKV-6 / C DKV-9 / C DKV-9 / D Standard paint finish SL In the Hoval colours red (RAL 3000) and orange (RAL 2008). Special paint finish AL In RAL colour No. 43

46 TopVent DKV Specification Texts Room temperature control with the TempTronic Electronic controller with 2-speed 2-point control, fuzzy logic, clock with automatic summer / winter changeover and holiday programme. TempTronic SHK, controller for heating and cooling operation, built as wall unit in a plastic casing with transparent lid, room air sensor included TempTronic SHK-S, controller for heating and cooling operation, built for installation in a control panel (without casing, transformer, contactors and fuses), room air sensor included Three additional room air sensors for averaging TS1M Cylinder lock ZS for TempTronic wall unit Automatic air distribution control with the VarioTronic Electronic controller with well-proven control algorithm for changing operating conditions. VarioTronic VT-W, control module built as wall unit, in a plastic casing with transparent lid VarioTronic VT-S, control module for installation in a control panel (without casing, transformer, contactor and fuses) Cylinder lock ZS for VarioTronic wall unit Actuator VT-AK with cable, plug, supply air sensor and room air sensor Actuator VT-AS with cable and plug Separate room air sensor TS1 Manual air distribution control with the potentiometer Manual control by means of a potentiometer and actuator with a range of 0 to 50 for adjustment of the air discharge angle between vertical and horizontal. Potentiometer wall unit PMS-W Potentiometer for installation in a control panel PMS-S Actuator VT-AS with cable and plug Transformer TA for maximum 7 actuators 44

47 TopVent NHV D Recirculation unit for heating high spaces with lower comfort requirements (e.g. high rack warehouses) 1 Intended use 46 2 Function and construction 47 3 Technical data 48 4 Options 56 5 Control systems 57 6 System design 58 7 Transport and installation 60 8 Specification texts 62

48 TopVent NHV Intended Use 1 Intended use TopVent NHV are recirculation unit heaters for use in high spaces. Correct usage also entails adherence to the manufacturer's conditions for installation, initial start-up, operation and maintenance (operating instructions) as well as consideration of possible malfunctions and of hazards. 1.1 User group TopVent units are only to be installed, operated and serviced by authorised and trained specialists who are familiar with and have been instructed on the hazards. The operating instructions are for English-speaking works engineers and technicians as well as specialists in building, heating and ventilation technology. 1.2 Modes of operation TopVent NHV units have the following operating modes: Recirculation heating at low fan speed Recirculation heating at high fan speed Standby Off The application limits given in the 'Technical Data' section must be observed. Any utilisation beyond this is considered inappropriate. The manufacturer is not liable for any damages resulting therefrom. In standard design the units are not suitable for use in explosive atmospheres, in high humidity areas or in rooms with a high dust load. 1.3 Hazards Despite all of the preventive measures that have been taken, there are certain hazards, which may not be obvious, e.g.: Danger when working on the electrical system Items (e.g. tools) can drop down when work is being done on the TopVent unit Malfunctions due to defective parts Danger from hot water when working on the heating system 46

49 TopVent NHV Function and Construction 2 Function and construction Heating section The TopVent NHV unit is used for cost-effective recirculation heating in high spaces. The unit is installed under the ceiling. It takes in room air, heats it by means of the heater battery and injects it back into the room via the outlet nozzle. The air discharge angle cannot be adjusted with the TopVent NHV. Therefore the unit is specially suited for applications where comfort requirements are relatively low (e.g. high racking warehouses). Thanks to its high efficiency the TopVent NHV unit heater covers a large area. Therefore, in comparison with other systems, fewer units are needed to achieve the required environment. Three unit sizes, two-speed fans, different heater battery types and a wide variety of accessories provide a tailored solution for each application. Furthermore, special batteries (steam, electrical heating) are also available. The TopVent NHV consists of the heating section (with fan and heater battery) and the outlet nozzle. These two components are bolted together and can be dismantled, even after installation. Outlet nozzle Fig. D2 1: TopVent NHV unit components D Casing: consisting of corrosion-resistant Aluzinc sheet steel Fan: axial fan with low energy consumption, quiet and maintenance free Heat exchanger: LPHW heater battery consisting of copper tubes with aluminium fins Terminal box Outlet nozzle Fig. D2 2: Construction of TopVent NHV 47

50 TopVent NHV Technical Data 3 Technical data Unit type Fan speed RPM (nominal) min -1 Nominal air flow rate m³ / h Floor area reached 1) max. m² Power consumption (at 400 V / 50 Hz) kw Current consumption (at 400 V / 50 Hz) A NHV-6 / A I NHV-6 / B I NHV-6 / C I Unit type Fan speed RPM (nominal) min -1 Nominal air flow rate m³ / h Floor area reached 1) max. m² Power consumption (at 400 V / 50 Hz) kw Current consumption (at 400 V / 50 Hz) A NHV-9 / A I NHV-9 / B I NHV-9 / C I Unit type Fan speed RPM (nominal) min -1 Nominal air flow rate m³ / h Floor area reached 1) max. m² Power consumption (at 400 V / 50 Hz) kw Current consumption (at 400 V / 50 Hz) A NHV-10 / A I NHV-10 / B I NHV-10 / C I ) Mounting height H max = 12 m up to 30 K temperature difference supply air - room air Table D3 1: Technical data of TopVent NHV Unit type reference Unit type TopVent NHV Unit size 6, 9 or 10 Heat exchanger Coil type A, B or C NHV 6 / A Unit type Fan speed Sound pressure level (5 m distance) 1) db(a) Total sound power level db(a) Octave sound power level 63 Hz db 125 Hz db 250 Hz db 500 Hz db 1000 Hz db 2000 Hz db 4000 Hz db 8000 Hz db NHV-6 I NHV-9 I NHV-10 I ) with hemispherical radiation in a room with little reflection Table D3 2: Unit type reference Table D3 3: Sound level of TopVent NHV 48

51 TopVent NHV Technical Data NHV-6 Air inlet temperature LPHW Unit type C 90 / 70 NHV-6 / A I NHV-6 / B I NHV-6 / C I 80 / 60 NHV-6 / A I NHV-6 / B I NHV-6 / C I 10 C Q t S H max m W p W kw C m l / h kpa C Q t S H max m W p W kw C m l / h kpa C Q t S H max m W p W kw C m l / h kpa D 70 / 50 NHV-6 / A I NHV-6 / B I NHV-6 / C I / 40 NHV-6 / A I NHV-6 / B I NHV-6 / C I / 71 NHV-6 / A I NHV-6 / B I NHV-6 / C I Operating conditions not allowed because the maximum supply air temperature of 60 C is exceeded. Legend: Q = Heat output t S = Supply air temperature H max = Maximum mounting height m W = Water flow rate p W = Water pressure drop Table D3 4: Heat outputs of TopVent NHV-6 49

52 TopVent NHV Technical Data NHV-9 Air inlet temperature LPHW Unit type C 90 / 70 NHV-9 / A I NHV-9 / B I NHV-9 / C I 80 / 60 NHV-9 / A I NHV-9 / B I NHV-9 / C I 10 C Q t S H max m W p W kw C m l / h kpa C Q t S H max m W p W kw C m l / h kpa C Q t S H max m W p W kw C m l / h kpa / 50 NHV-9 / A I NHV-9 / B I NHV-9 / C I / 40 NHV-9 / A I NHV-9 / B I NHV-9 / C I / 71 NHV-9 / A I NHV-9 / B I NHV-9 / C I Operating conditions not allowed because the maximum supply air temperature of 60 C is exceeded. Legend: Q = Heat output t S = Supply air temperature H max = Maximum mounting height m W = Water flow rate p W = Water pressure drop Table D3 5: Heat outputs of TopVent NHV-9 50

53 TopVent NHV Technical Data NHV-10 Air inlet temperature LPHW Unit type C 90 / 70 NHV-10 / A I NHV-10 / B I NHV-10 / C I 80 / 60 NHV-10 / A I NHV-10 / B I NHV-10 / C I 10 C Q t S H max m W p W kw C m l / h kpa C Q t S H max m W p W kw C m l / h kpa C Q t S H max m W p W kw C m l / h kpa D 70 / 50 NHV-10 / A I NHV-10 / B I NHV-10 / C I / 40 NHV-10 / A I NHV-10 / B I NHV-10 / C I / 71 NHV-10 / A I NHV-10 / B I NHV-10 / C I Operating conditions not allowed because the maximum supply air temperature of 60 C is exceeded. Legend: Q = Heat output t S = Supply air temperature H max = Maximum mounting height m W = Water flow rate p W = Water pressure drop Table D3 6: Heat outputs of TopVent NHV-10 51

54 TopVent NHV Technical Data 28 E 4 x M10 T G H B N F J C Return Flow R D A Unit type A mm B mm C mm T mm E mm F mm G mm H mm J " N mm R mm D mm Weight kg Water content Type of heater battery l NHV Rp 1¼ (female) A B C NHV Rp 1½ (female) A B C NHV Rp 1½ (female) A B C Table D3 7: Dimensions and weights of TopVent NHV Maximum operating pressure 800 kpa Maximum heating medium temperature 120 C Maximum supply air temperature 60 C Maximum ambient temperature 40 C Table D3 8: Application limits of TopVent NHV 52

55 TopVent NHV Technical Data Z D R W X Y Unit type Fan speed Unit height R m Wall distance W min. m max. m Unit distance X min. m (centre to centre) max. m Mounting height Y min. m Ceiling distance Z min. m NHV-6 / A I NHV-6 / B I NHV-6 / C I Unit type Fan speed Unit height R m Wall distance W min. m max. m Unit distance X min. m (centre to centre) max. m Mounting height Y min. m Ceiling distance Z min. m NHV-9 / A I NHV-9 / B I NHV-9 / C I Unit type Fan speed Unit height R m Wall distance W min. m max. m Unit distance X min. m (centre to centre) max. m Mounting height Y min. m Ceiling distance Z min. m NHV-10 / A I NHV-10 / B I NHV-10 / C I Table D3 9: Minimum and maximum distances 53

56 TopVent NHV Technical Data Pressure drop increase in Pa NHV-6 / A NHV-6 / B NHV-6 / C NHV-6 / A NHV-6 / B NHV-6 / C Example: An additional pressure drop of 49 Pa at 6280 m³/h results in a new air flow rate of 5440 m³/h. speed speed speed speed I speed I speed I Air flow rate in m³ / h Diagram D3 1: Air flow rate for TopVent NHV-6 with additional pressure drop Pressure drop increase in Pa NHV-9 / A NHV-9 / B NHV-9 / C NHV-9 / A NHV-9 / B NHV-9 / C speed speed speed speed I speed I speed I Air flow rate in m³ / h Diagram D3 2: Air flow rate for TopVent NHV-9 with additional pressure drop 54

57 TopVent NHV Technical Data Pressure drop increase in Pa NHV-10 / A speed NHV-10 / B speed NHV-10 / C speed NHV-10 / A speed I NHV-10 / B speed I NHV-10 / C speed I D Air flow rate in m³ / h Diagram D3 3: Air flow rate for TopVent NHV-10 with additional pressure drop 55

58 TopVent NHV Options 4 Options A wide range of accessories allows customisation of TopVent NHV units for each individual project. For a detailed description of all optional components please refer to part K 'Options' of this handbook. Paint finish Suspension set Isolation switch Recirculation silencer Explosion-proof components In the Hoval standard colours red / orange (for free) or in any desired colour (extra charge) For fastening the unit to the ceiling External on / off mains switch For lowering the noise level in the room (reduced noise reflection from the ceiling) For use of TopVent NHV in explosive areas (zone 1 and zone 2), only for NHV-6 and NHV-9 Table D4 1: Options available with TopVent NHV 56

59 TopVent NHV Control Systems 5 Control systems For TopVent NHV units, specially developed and optimised components for room temperature control are available from Hoval. For a detailed description of these components please refer to part L 'Control systems' of this handbook. D TempTronic EasyTronic This is a programmable, electronic temperature controller allowing fully automatic operation. Its control algorithm with fuzzy logic ensures smallest room temperature deviations from setpoints and minimises energy consumption. This is a basic temperature controller without clock. The desired room temperature is manually adjusted and the fan speed selected with a switch. Table D5 1: Room temperature control systems for TopVent NHV For indoor climate systems where TopVent NHV units are combined with RoofVent fresh air units all control is by Hoval DigiNet. 57

60 TopVent NHV System Design 6 System design Example Collect basic data Space dimensions (floor plan) Mounting height (= distance from floor to underside of the TopVent unit) Required heat output Desired room temperature Heating medium temperature (flow / return) Space dimensions...38 m x 62 m Mounting height...15 m Required heat output kw Desired room temperature...15 C Heating medium temperature / 50 C Mounting height With the minimum mounting height (table D3-9) check which units can be used. Check maximum mounting height according to heating medium temperature and inlet air temperature (= room temperature) (tables D3-4, D3-5 and D3-6). Eliminate units that cannot be used. According to table D3-9 the minimum mounting heights are: NHV m NHV m NHV m Consequently, all sizes can be used in this project with a mounting height of 15 m. According to tables D3-4, D3-5 and D3-6 and the given conditions (heating medium temperature 70 / 50 C, inlet air temperature 15 C) the following unit types cannot be employed due to the maximum mounting height: NHV-6 / B... H max = 12.9 m NHV-6 / C... H max = 9.4 m NHV-9 / B... H max = 14.5 m NHV-9 / C... H max = 10.8 m NHV-10 / C... H max = 12.2 m Minimum and maximum number of units For determining the minimum number of units three criteria must be fulfilled: a) Minimum number relating to floor area Table D3-1 indicates the maximum floor area that can be reached with TopVent NHV units. With these values and the given floor area the minimum number of units can be determined for each unit size and coil type. b) Minimum number relating to space dimensions (length x width) Depending on space dimensions, a certain minimum number of units are required in the length and in the width. This can be calculated from the maximum distances between units and to the wall (see table D3-9). c) Minimum number relating to heat output The minimum number for each unit size and coil type can be calculated from the required total heat output (tables D3-4, D3-5 and D3-6). Calculate the minimum numbers according to a), b) and c) for each unit type and enter them in a table. Then take the highest value as minimum number of units d). Calculate the maximum possible number according to e) and enter the values in the table. 58

61 TopVent NHV System Design d) Effective minimum number of units The highest value of the foregoing calculations a), b) and c) is the effective minimum number of units that should be installed. e) Maximum number of units The minimum number determined under d) normally corresponds to the solution selected in practice as it incurs the lowest costs. Yet if comfort requirements are particularly high more units may be provided. The maximum number of units is theoretically determined from the total floor area divided by the minimum floor area reached per unit X 2 (X = minimum distance between units, see table D3-9). Type a) b) c) d) e) NHV-6 / A NHV-6 / B no solution NHV-6 / C no solution NHV-9 / A NHV-9 / B no solution NHV-9 / C no solution NHV-10 / A NHV-10 / B NHV-10 / C no solution D Definite number of units According to space dimensions, comfort requirements and costs, select the optimum solution from the remaining alternatives. Due to the space dimensions, comfort requirements and the investment made available the solution with 5 TopVent NHV-10 / B is selected from the remaining variants. Automatic control Group units working under equal operating conditions (room temperature, heat demand, operating times) into control zones. Check maximum switching power of the controller. The low-cost solution is 2 TempTronic controllers: Switching power = 3 x 1.53 kw < 6.5 kw 2 x 1.53 kw < 6.5 kw 59

62 TopVent NHV Transport and Installation 7 Transport and installation Transport and installation to be carried out by experts only! A lifting appliance is required for transportation and installation of the units! Do not tilt or lay the unit on its side! 7.1 Installation For fastening to the ceiling, the unit is equipped with four M10 captive nuts with hexagon head screws and washers as standard. With these and the height adjustable suspension set (option) the unit is easily fixed to the ceiling. The captive nuts are only designed for the unit's own weight. Do not put on any additional loads! The captive nuts cannot sustain a bending moment; therefore do not use eyebolts! Installation by means of steel flat, slotted steel flat, angle or steel wire is also possible, but the following has to be considered: 7.2 Hydraulic installation Hydraulic installation to be carried out by experts only! Combine units working under equal operating conditions (room temperature, heat gain, operating time, etc.) into one control zone. Low or medium pressure hot water up to 120 C can be used as a heating medium. To save energy, the distributor can be pre-calibrated; it should, however, be ensured that the heat requirement of each heater battery can always be met. Connect the individual heating coils as shown in figure D7 2. Depending on local conditions, it should also be considered whether compensations for flow and return pipework are needed to balance the longitudinal expansion and / or flexible connections for the units. The heat exchanger cannot take up any extra load, e.g. through the flow or return pipe. The individual units within a control zone must be hydraulically balanced to ensure even temperatures. Non-vertical suspensions are permissible up to a maximum angle of 45. The unit must be installed with its top face horizontal (level)! max. 45 max. 45 Air vent Balancing valve Drain cocks Isolating valves Flow Return Fig. D7 1: Suspension of TopVent NHV Fig. D7 2: Heating coil connection 60

63 TopVent NHV Transport and Installation 7.3 Electrical installation The electrical connections to the unit must be carried out by an electrical expert. Relevant regulations must be observed. D The unit is delivered ready for use. Check that the local operating voltage, frequency and fusing are in accordance with the information on the nameplate. If any discrepancies occur the unit must not be connected! Check cable diameters when using long wiring runs. Electrical installation to be carried out according to the wiring diagram for the control equipment. Connection of the TopVent units to be carried out according to the wiring diagram. Connect thermal relays built into the motor; otherwise the motor is not protected against overheating. Do not forget to install a main switch for the whole system (control, units). Several TopVent units can be connected in parallel. Thermal relays and isolation switches must be wired in series! Isolation switch (optional) Low fan speed (Y connection) Fan (wiring by the installer) High fan speed ( connection) Thermal relay (wiring by the installer) Fig. D7 3: Wiring diagram for TopVent NHV 61

64 TopVent NHV Specification Texts 8 Specification texts TopVent NHV Recirculation unit for heating high spaces with lower comfort requirements Recirculation silencer USD Fitted on top of the unit, made of Aluzinc sheet steel with sound-insulation inlay, insertion attenuation 3 db(a). Casing made of corrosion-resistant Aluzinc sheet steel. For fastening to the ceiling, the unit is equipped with four M10 captive nuts with hexagon head screws and washers as standard. Heat exchanger of copper tubes with aluminium fins. Headers are made of steel. Fan unit consisting of a 2-speed three-phase motor of the external-rotor type with rigid sickle-shaped aluminium blade impeller, maintenance-free and quiet at high efficiency. Motor protection with built-in thermal relays. Protection rating IP54. Terminal box built into the casing sidewall for connection of mains supply and accessories. Concentric outlet nozzle. Technical data Fan speed I Nominal air flow rate m³ / h Floor area reached m² Mounting height m Nominal heating capacity kw with LPHW C and air inlet temperature C Power consumption kw Current consumption A Voltage 400 V / 50 Hz NHV-6 / A NHV-6 / B NHV-6 / C NHV-9 / A NHV-9 / B NHV-9 / C NHV-10 / A NHV-10 / B NHV-10 / C Standard paint finish SL In the Hoval colours red (RAL 3000) and orange (RAL 2008). Special paint finish AL In RAL colour No. Suspension set AHS For fastening the units to the ceiling, consisting of 4 pairs of Aluzinc steel U sections, height adjustable up to 1300 mm. Paint finish as for the unit. Isolation switch RS In the terminal box of the TopVent unit. 62

65 TopVent NHV Specification Texts TopVent NHV EEx Recirculation unit with explosion-proof components for heating high spaces with lower comfort requirements Casing made of corrosion-resistant Aluzinc sheet steel. For fastening to the ceiling, the unit is equipped with four M10 captive nuts with hexagon head screws and washers as standard. Incl. measures avoiding electrostatic charge. Heat exchanger of copper tubes with aluminium fins. Headers are made of steel. Fan unit consisting of a 1-speed radial fan in explosionproof design. Motor protection with built-in PTC resistor. Protection rating IP44. Terminal box built into the casing sidewall for connection of mains supply and accessories. Concentric outlet nozzle. Technical data Nominal air flow rate m³ / h Floor area reached m² Mounting height m Nominal heating capacity kw with LPHW C and air inlet temperature C Power consumption kw Current consumption A Voltage 400 V / 50 Hz NHV-6 / A EEx NHV-6 / B EEx NHV-6 / C EEx NHV-9 / A EEx NHV-9 / B EEx NHV-9 / C EEx Room temperature control with the TempTronic Electronic controller with 2-speed 2-point control, fuzzy logic, clock with automatic summer / winter changeover and holiday programme. TempTronic SH, controller for heating operation, built as wall unit in a plastic casing with transparent lid, room air sensor included TempTronic SH-S, controller for heating operation, built for installation in a control panel (without casing, transformer, contactors and fuses), room air sensor included Three additional room air sensors for averaging TS1M Cylinder lock ZS for TempTronic wall unit Room temperature control with the EasyTronic Basic controller with 2-point control and manual fan speed switching. EasyTronic ET, controller for heating operation, built as wall unit in a plastic casing with transparent lid, room thermostat included D Standard paint finish SL In the Hoval colours red (RAL 3000) and orange (RAL 2008). Special paint finish AL In RAL colour No. Suspension set AHS For fastening the units to the ceiling, consisting of 4 pairs of Aluzinc steel U sections, height adjustable up to 1300 mm. Paint finish as for the unit. 63

66 64

67 TopVent commercial CAU E Roof unit for ventilating, heating and cooling supermarkets 1 Intended use 66 2 Function and construction 66 3 Technical data 68 4 Option 74 5 Control systems 75 6 System design 76 7 Transport and installation 78 8 Specification texts 80

68 TopVent commercial CAU Intended Use 1 Intended use 2 Function and construction TopVent commercial CAU are used for ventilating, heating and cooling large spaces in fresh air, mixed air or recirculation operation. Correct usage also entails adherence to the manufacturer's conditions for installation, initial start-up, operation and maintenance (operating instructions) as well as consideration of possible malfunctions and of hazards. 1.1 User group TopVent units are only to be installed, operated and serviced by authorised and trained specialists who are familiar with and have been instructed on the hazards. The operating instructions are for English-speaking works engineers and technicians as well as specialists in building, heating and ventilation technology. 1.2 Modes of operation TopVent commercial CAU have the following operating modes: Fresh air, mixed air or recirculation operation at low fan speed ( % fresh air) Fresh air, mixed air or recirculation operation at high fan speed ( % fresh air) Standby Off The application limits given in the 'Technical Data' section must be observed. Any utilisation beyond this is considered inappropriate. The manufacturer is not liable for any damages resulting therefrom. The units are not suitable for use in explosive atmospheres, in high humidity areas or in rooms with a high dust load. The TopVent commercial CAU is used for ventilating, heating and cooling in fresh air, mixed air or recirculation modes; it has been specially developed for application in hypermarkets and supermarkets. The unit is installed in the roof with the integrated roof frame. Depending on the damper position, it takes in fresh air and / or room air, filters it, heats or cools it and injects it back into the room via the Air-Injector. Thanks to its powerful and efficient air distribution the TopVent commercial CAU covers a large area. Therefore, in comparison with other systems, fewer units are needed to achieve the required environment. As the units are installed in the roof, they do not protrude far into the room and maintenance works are carried out from roof level, without disruption of business. 2.1 Unit construction The TopVent commercial CAU consists of the following components: Roof hood for fresh air (with two weather protection grilles, inspection door, two filters G4 and differential pressure switch for filter supervision) Mixed air box (with fresh air / recirculation dampers and actuator) Roof frame Heating / cooling section (with fan, heat exchanger and built-in condensate separator) Automatically adjustable vortex air distributor Air-Injector To avoid condensation on the outer surface the roof hood and the heating / cooling section are insulated. The components are bolted together and can be dismantled, even after installation. 1.3 Hazards Despite all of the preventive measures that have been taken, there are certain hazards, which may not be obvious, e.g.: Danger when working on the electrical system Items (e.g. tools) can drop down when work is being done on the TopVent unit Malfunctions due to defective parts Danger from hot water when working on the heating system Roof hood for fresh air Mixed air box Roof frame Heating / cooling section Air-Injector Fig. E2 1: TopVent commercial CAU unit components 66

69 TopVent commercial CAU Function and Construction Casing: consisting of corrosion-resistant Aluzinc sheet steel Fan: axial fan with low energy consumption, quiet and maintenance-free Heat exchanger: LPHW / chilled water coil consisting of copper tubes with aluminium fins Condensate separator: with condensate drain connection Frost stat: installed on the heat exchanger Terminal box: with isolation switch, easily accessible behind the inspection door Air-Injector: patented, automatically adjustable vortex air distributor for draught-free air distribution over a large area Mixed air box: with fresh air / recirculation dampers (made from aluminium extrusions with plastic gear wheels) and actuator Roof hood: insulated, easily removable with four hand grips, with two weather protection grilles, two filters G4 and differential pressure switch for filter supervision Roof frame: made of sheet steel E Fig. E2 2: Construction of TopVent commercial CAU 2.2 Air distribution with the Air-Injector The patented air distributor called the Air-Injector is the core element. Its controllable vane arrangement allows continuous adjustment of the air discharge angle. The setting depends on the air flow rate ( fan speed), the mounting height and the temperature difference between supply air and room air. Thus the air is injected into the room either vertically downwards, conically or horizontally, ensuring that a large floor area is reached with each TopVent commercial CAU no draughts occur in the occupied area temperature stratification in the room is reduced and thus energy is saved. 67

70 TopVent commercial CAU Technical Data 3 Technical data Unit type Fan speed RPM (nominal) min -1 Nominal air flow rate m³ / h Floor area reached 1) max. m² Power consumption (at 400 V / 50 Hz) kw Current consumption (at 400 V / 50 Hz) A CAU-9 I ) Mounting height H max = 9 m up to 30 K temperature difference supply air - room air Table E3 1: Technical data of TopVent commercial CAU Unit type reference Unit type TopVent commercial CAU Unit size Size 9 Electrical connection D4 = DigiNet design KK = Terminal box design CAU 9 / D4 Unit type Fan speed Sound pressure level (5 m distance) 1) Total sound power level Octave sound power level 1) with hemispherical radiation in a room with little reflection db(a) db(a) 63 Hz db 125 Hz db 250 Hz db 500 Hz db 1000 Hz db 2000 Hz db 4000 Hz db 8000 Hz db CAU-9 I Table E3 2: Unit type reference Table E3 3: Sound level of TopVent commercial CAU 68

71 TopVent commercial CAU Technical Data Air inlet temperature 1) LPHW Unit type C 10 C Q t S H max m W p W kw C m l / h kpa 15 C Q t S H max m W p W kw C m l / h kpa 20 C Q t S H max m W p W kw C m l / h kpa 90 / 70 CAU-9 I 80 / 60 CAU-9 I 70 / 50 CAU-9 I E 60 / 40 CAU-9 I / 71 CAU-9 I 1) The air inlet temperatures (10/ 15 / 20 C) correspond to room air temperature. The given heat outputs relate to a fresh air rate of 20 % (at -10 C); i.e. the mixed temperatures at the coil inlet are 6 / 10 / 14 C. Operating conditions not allowed because the maximum supply air temperature of 60 C is exceeded. Legend: Q = Heat output t S = Supply air temperature H max = Maximum mounting height m W = Water flow rate p W = Water pressure drop Table E3 4: Heat outputs of TopVent commercial CAU 69

72 TopVent commercial CAU Technical Data Cooling medium temp. t ai 1) rh Unit type C % 6 / 12 C Q tot Q sen t S m C m W p W kw kw C kg / h l / h kpa 8 / 14 C Q tot Q sen t S m C m W p W kw kw C kg / h l / h kpa 10 / 16 C Q tot Q sen t S m C m W p W kw kw C kg / h l / h kpa CAU-9 I 50 CAU-9 I 70 CAU-9 I CAU-9 I 50 CAU-9 I 70 CAU-9 I CAU-9 I 50 CAU-9 I 70 CAU-9 I ) The air inlet temperatures (24/ 26 / 28 C) correspond to room air temperature. The given cooling capacities relate to a fresh air rate of 20 % (at + 32 C); i.e. the mixed temperatures at the coil inlet are 25.6 / 27.2 / 28.8 C. Legend: t ai = Air inlet temperature rh = Air inlet humidity Q tot = Total cooling capacity Q sen = Sensible cooling capacity p W = Water pressure drop Table E3 5: Cooling capacity of TopVent commercial CAU-9 t S m C m W = Supply air temperature = Amount of condensate = Water flow rate 70

73 TopVent commercial CAU Technical Data E Rp 2" Rp ¾" Rp 2" Roof frame: Unit type Weight Water content of coil kg l CAU Table E3 6: Dimensions and weights of TopVent commercial CAU Maximum operating pressure 800 kpa Maximum heating medium temperature 120 C Maximum supply air temperature 60 C Maximum ambient temperature 40 C Maximum amount of condensate Minimum air flow rate Table E3 7: Application limits of TopVent commercial CAU 90 kg m³ / h 71

74 TopVent commercial CAU Technical Data W X Y Unit type Fan speed Wall distance W min. m max. m Unit distance X min. m (centre to centre) max. m Mounting height Y min. m CAU-9 I Table E3 8: Minimum and maximum distances 72

75 TopVent commercial CAU Technical Data CAU-9 speed CAU-9 speed I 100 Pressure drop increase in Pa Example: An additional pressure drop of 46 Pa at 6800 m³/h results in a new air flow rate of 6180 m³/h. E Air flow rate in m³ / h Diagram E3 1: Air flow rate for TopVent commercial CAU-9 with additional pressure drop 73

76 TopVent commercial CAU Options 4 Options A wide range of accessories allows customisation of TopVent commercial CAU for each individual project. For a detailed description of all optional components please refer to part K 'Options' of this handbook. Paint finish Actuator for Air-Injector Acoustic cowl Insulation Condensate pump Hydraulic assembly In the Hoval standard colours red / orange (for free) or in any desired colour (extra charge) For adjustment of the Air-Injectors when using a non-hoval control system (for Hoval control equipment see section 5 'Control systems') For lowering the noise level in the room (reduced noise radiation from the Air-Injector) Prevents condensation forming on the outer surfaces of the Air-Injector For condensate drainage through waste water pipes under the ceiling or onto the roof Prefabricated hydraulic assembly for diverting system Table E4 1: Options available with TopVent CAU 74

77 TopVent commercial CAU Control Systems 5 Control systems For TopVent commercial CAU, specially developed and optimised components for room temperature, air distribution and fresh air rate control are available from Hoval. For a detailed description of these components please refer to part L 'Control systems' of this handbook. 5.1 Integrated system DigiNet (detailed description on request) Ideally, TopVent commercial CAU are controlled by DigiNet. This is an integrated system that has been specially developed for Hoval indoor climate systems. It controls room temperature as well as air distribution and constantly optimises the fresh air rate (i.e. just as much fresh air is taken in as necessary to maintain the room temperature without additional heating or cooling). For control by DigiNet, a DigiUnit terminal box is installed in the TopVent commercial CAU (instead of the standard terminal box). Table E5 1: Integrated control system for TopVent commercial CAU E 5.2 Room temperature control TempTronic This is a programmable, electronic temperature controller allowing fully automatic operation. Its control algorithm with fuzzy logic ensures smallest room temperature deviations from setpoints and minimises energy consumption. Table E5 2: Room temperature control systems for TopVent commercial CAU 5.3 Air distribution control Automatic control with the VarioTronic The VarioTronic is an electronic controller for the Air-Injector. It adjusts air distribution for changing operating conditions (fan speed, temperature difference between supply air and room air) and works independently of room temperature control. Manual control by means of potentiometer and actuator Where operating conditions change rarely or comfort requirements are not so high, air distribution may be controlled manually by means of a potentiometer. Fixed adjustment Where the basic conditions remain unchanged (constant supply air temperature, constant air flow rate), air distribution can be manually fixed at commissioning. Table E5 3: Air distribution control systems for TopVent commercial CAU 5.4 Fresh air rate control Manual control by means of potentiometer and actuator Where comfort requirements are not so high, the fresh air rate may be controlled manually by means of a potentiometer. Table E5 4: Fresh air rate control systems for TopVent commercial CAU 75

78 TopVent commercial CAU System Design 6 System design Example Usually, the primary function of TopVent commercial CAU is cooling; for this reason the design process is described for this function. The design for heating can be made in a similar way to the example in part G 'TopVent MH'. Collect basic data Space dimensions (floor plan) Mounting height (= distance from floor to underside of the TopVent unit) Required cooling capacity Desired room conditions Cooling medium temperature (flow / return) Comfort requirements (acoustic) Fresh air temperature Minimum fresh air flow rate (The fresh air rate can be adjusted as desired between 0 % and 100 %; for an efficient use of energy the design calculation is to be based on a minimum value.) Space dimensions...65 m x 75 m Mounting height...6 m Required cooling capacity kw Desired room conditions...24 C / 50 % Cooling medium temperature / 16 C Comfort requirements...standard Fresh air temperature...32 C Minimum fresh air flow rate m³ / h Comfort requirements (acoustic) According to acoustic requirements define the fan speed: Low sound level low fan speed (speed I) Normal sound level high fan speed (speed ) In this project the acoustic requirements are 'standard', hence use the high fan speed (speed ) for design calculations. Mounting height With the minimum mounting height (table E3-8) check which units can be used. According to table E3-8 the minimum mounting height is: CAU m Consequently, all sizes can be used in this project with a mounting height of 6 m. Minimum and maximum number of units For determining the minimum number of units three criteria must be fulfilled: a) Minimum number relating to floor area Table E3-1 indicates the maximum floor area that can be reached with TopVent commercial CAU units. With these values and the given floor area the minimum number of units can be determined for each unit size and coil type. b) Minimum number relating to space dimensions (length x width) Depending on space dimensions, a certain minimum number of units are required in the length and in the width. This can be calculated from the maximum distances between units and to the wall (see table E3-8). Calculate the minimum numbers according to a), b) and c) for each unit type and enter them in a table. Then take the highest value as minimum number of units d). Calculate the maximum possible number according to e) and enter the values in the table. 76

79 TopVent commercial CAU System Design c) Minimum number relating to cooling capacity The minimum number for each unit size and coil type can be calculated from the required total cooling capacity (table E3-5). Please note that only the sensible cooling capacity Q sen is available for cooling of the space while the total capacity Q tot must be used for sizing the chiller. Type a) b) c) d) e) CAU d) Effective minimum number of units The highest value of the foregoing calculations a), b) and c) is the effective minimum number of units that should be installed. e) Maximum number of units The minimum number determined under d) normally corresponds to the solution selected in practice as it incurs the lowest costs. Yet if comfort requirements are particularly high more units may be provided. The maximum number of units is theoretically determined from the total floor area divided by the minimum floor area reached per unit X 2 (X = minimum distance between units, see table E3-8). E Definite number of units According to space dimensions, comfort requirements and costs, select the optimum solution from the remaining alternatives. Due to the space dimensions, comfort requirements and the investment made available the solution with 9 TopVent commercial CAU-9 is selected. Fresh air rate Calculate the minimum fresh air rate from the air flow rate of the selected units (see table E3-1) and the required minimum fresh air flow rate. Total air flow rate: 9 x 6800 m³ / h = m³ / h Minimum fresh air flow rate: m³ / h Minimum fresh air rate: 20 % Automatic control Ideally, TopVent commercial CAU are controlled by DigiNet; this system is perfectly suited to control all unit functions. If a TempTronic is used for room temperature control, check maximum switching power. The maximum floor area reached depends on the one hand on local conditions and on the other hand on the quality of air distribution. Due to the complexity of air flow mechanisms in large rooms the design quantities can only partly be mathematically described. The quality of the air distributor affects the supplied energy made available in the occupied area as a function of the air flow rate, the temperature difference between supply air and room air and the mounting height. Tests on the test rig and the experience of numerous applications show that with the Air-Injector this conversion of energy is effected with considerably higher efficiency than with other air distributors usually employed in recirculation units. This higher quality leads to lower running costs as well as to a larger floor area reached and thus fewer units are needed. To facilitate the design process concerning the floor area reached we have decided to dispense with complicated formulas and diagrams. However, it is important to keep to the limiting values and to make sure that the primary and secondary air flow can spread unhindered. If the given limits are exceeded in your application please seek Hoval advice. 77

80 TopVent commercial CAU Transport and Installation 7 Transport and installation Transport and installation to be carried out by experts only! A lifting appliance is required for transportation and installation of the units! Do not tilt or lay the unit on its side! 7.1 Installation The TopVent commercial CAU comes completely assembled with roof frame and roof hood. Installation is carried out from roof level: Hook lifting gear into the four lugs at the side of the unit. Lift the unit and turn the coil connections in the required position. Place the unit onto the roof opening and secure it. Insulate and seal the roof frame from the outside. The roof frame support must be level and horizontal. Alternatively, the unit can be installed in two steps: First install the roof frame with the roof hood, then take off the roof hood and insert the ventilation unit from above. 7.2 Hydraulic installation Hydraulic installation to be carried out by experts only! For easy and quick hydraulic installation use the options 'Hydraulic assembly' and 'Condensate pump'! Combine units working under equal operating conditions (room temperature, heat gain, operating time, etc.) into one control zone. Low or medium pressure hot water up to 120 C can be used as a heating medium. To save energy, the distributor can be pre-calibrated; it should, however, be ensured that the heat requirement of each heater battery can always be met. Connect the individual heating / cooling coils as shown in figure E7 1. Depending on local conditions, it should also be considered whether compensations for flow and return pipework are needed to balance the longitudinal expansion and / or flexible connections for the units. The heat exchanger cannot take up any extra load, e.g. through the flow or return pipe. Adequately size the slope and cross section of the condensate drain to prevent a condensate backwash. Install a 200 mm trap. The individual units within a control zone must be hydraulically balanced to ensure even temperatures. Air vent Balancing valve Drain cocks Isolating valves Flow Return Condensate drain (with trap) 2-port valve Fig. E7 1: Heating / cooling coil connection 78

81 TopVent commercial CAU Transport and Installation 7.3 Electrical installation The electrical connections to the unit must be carried out by an electrical expert. Relevant regulations must be observed. The unit is delivered ready for use. Check that the local operating voltage, frequency and fusing are in accordance with the information on the nameplate. If any discrepancies occur the unit must not be connected! Check cable diameters when using long wiring runs. Electrical installation to be carried out according to the wiring diagram for the control equipment. Connection of the TopVent units to be carried out according to the wiring diagram. E Connect thermal relays built into the motor; otherwise the motor is not protected against overheating. Do not forget to install a main switch for the whole system (control, units). Several TopVent units can be connected in parallel. Thermal relays and isolation switches must be wired in series! The condensate separator only works with the fan running. Therefore, switch off the cooling pump together with the fan. For TopVent commercial CAU in DigiNet design, electrical installation by the installer only requires: Mains supply (3 x 400 VAC / 50 Hz) LON bus cable (2 x 0.5 mm² twisted, input and output) Plug connection between mixing valve and DigiUnit terminal box Actuator for Air-Injector Supply air sensor (option) Room air sensor (option) Cooling valve (option) Recirculation damper Filter pressure switch Frost stat Condensate pump control (option) For TopVent commercial CAU in terminal box design the following electrical connections are to be provided by the installer: Mains supply (3 x 400 VAC / 50 Hz) Thermal relay Supply air sensor (option) Filter pressure switch Frost stat Actuator for mixed air box Actuator for Air-Injector (option) Condensate pump (option) Plug connection between mixing valve and terminal box (option) Isolation switch Supply air fan 2-speed Thermal relay Condensate pump (option) Fig. E7 2: Wiring diagram for TopVent commercial CAU in terminal box design 79

82 TopVent commercial CAU Specification Texts 8 Specification texts TopVent commercial CAU Roof unit for ventilating, heating and cooling supermarkets Casing made of corrosion-resistant Aluzinc sheet steel, heating / cooling section insulated inside. Heat exchanger of copper tubes with aluminium fins. Headers are made of steel. A frost stat is included. A condensate separator with drain connection is installed. Fan unit consisting of a 2-speed three-phase motor of the external-rotor type with rigid sickle-shaped aluminium blade impeller, maintenance-free and quiet at high efficiency. Motor protection with built-in thermal relays. Protection rating IP54. Vortex air distributor with concentric outlet nozzle, twelve adjustable guide vanes and integrated sound attenuation cowl. Supporting roof frame made of galvanised sheet steel, with black paint-finish and four lifting lugs. Roof hood made of Aluzinc sheet steel, with internal insulation, two weather protection grilles and inspection door. Two fresh air filters class G4 with differential pressure switch for filter supervision. Mixed air box made of Aluzinc sheet steel with fresh air / recirculation dampers, incl. actuator. Terminal box built into the roof hood, easily accessible behind the inspection door. The following components are installed: Isolation switch Connection terminals The unit components are completely wired. Variant: DigiNet design DigiUnit terminal box as part of the digital control system Hoval DigiNet. The DigiUnit terminal box houses the highvoltage section with Isolation switch Motor protection per fan speed Fuse for electronics Transformer Relay for emergency operation Connection terminals and the DigiUnit controller. This controls the individual unit, including air distribution, and is to be linked to the other components of the Hoval DigiNet via LON bus. A supply air sensor is installed in the vortex air distributor. The unit components are completely wired. Technical data Fan speed I Nominal air flow rate m³ / h Floor area reached m² Mounting height m Nominal cooling capacity kw with chilled water C air inlet temperature C and air inlet humidity % Nominal heating capacity kw with LPHW C and air inlet temperature C Power consumption kw Current consumption A Voltage 400 V / 50 Hz CAU-9 Standard paint finish SL In the Hoval colours red (RAL 3000) and orange (RAL 2008). Special paint finish AL In RAL colour No. Actuator for Air-Injector VT-A Complete with cable, for adjustment of the Air-Injector when using a non-hoval control system. Acoustic cowl AHD Consisting of a sound attenuation cowl with bigger volume and a faceplate with sound-insulation lining, insertion attenuation 4 db(a). Insulation ID of the Air-Injector of the mixed air box Condensate pump KP Consisting of a centrifugal pump, collecting tray and flexible hose, delivery output max. 80 l / h at 3 m delivery height. Hydraulic assembly HG8D-AU Consisting of mixing valve with fast solenoid actuator, balancing valve STAD, ball valve, automatic air vent, drain cock and screw joints for coil connection and distribution circuit. 80

83 TopVent commercial CAU Specification Texts Room temperature control with the TempTronic Electronic controller with 2-speed 2-point control, fuzzy logic, clock with automatic summer / winter changeover and holiday programme. TempTronic SHK, controller for heating and cooling operation, built as wall unit in a plastic casing with transparent lid, room air sensor included TempTronic SHK-S, controller for heating and cooling operation, built for installation in a control panel (without casing, transformer, contactors and fuses), room air sensor included Three additional room air sensors for averaging TS1M Cylinder lock ZS for TempTronic wall unit E Automatic air distribution control with the VarioTronic Electronic controller with well-proven control algorithm for changing operating conditions. VarioTronic VT-W, control module built as wall unit, in a plastic casing with transparent lid VarioTronic VT-S, control module for installation in a control panel (without casing, transformer, contactor and fuses) Cylinder lock ZS for VarioTronic wall unit Actuator VT-AK with cable, plug, supply air sensor and room air sensor Actuator VT-AS with cable and plug Separate room air sensor TS1 Manual air distribution control with the potentiometer Manual control by means of a potentiometer and actuator with a range of 0 to 50 for adjustment of the air discharge angle between vertical and horizontal. Potentiometer wall unit PMS-W Potentiometer for installation in a control panel PMS-S Actuator VT-AS with cable and plug Transformer TA for maximum 7 actuators Manual fresh air rate control with the potentiometer Manual control by means of a potentiometer and actuator with a range of 0 to 90 for adjustment of the fresh air rate between 0 % and 100 %. Potentiometer wall unit PMS-W Potentiometer for installation in a control panel PMS-S Actuator MLK-A Transformer TA for maximum 7 actuators 81

84 82

85 TopVent commercial CUM F Roof unit for heating and cooling supermarkets 1 Intended use 84 2 Function and construction 84 3 Technical data 86 4 Options 92 5 Control systems 93 6 System design 94 7 Transport and installation 96 8 Specification texts 98

86 TopVent commercial CUM Intended Use 1 Intended use 2 Function and construction TopVent commercial CUM are used for heating and cooling large spaces in recirculation operation. Correct usage also entails adherence to the manufacturer's conditions for installation, initial start-up, operation and maintenance (operating instructions) as well as consideration of possible malfunctions and of hazards. 1.1 User group TopVent units are only to be installed, operated and serviced by authorised and trained specialists who are familiar with and have been instructed on the hazards. The operating instructions are for English-speaking works engineers and technicians as well as specialists in building, heating and ventilation technology. 1.2 Modes of operation TopVent commercial CUM have the following operating modes: Recirculation heating / cooling at low fan speed Recirculation heating / cooling at high fan speed Standby Off The application limits given in the 'Technical Data' section must be observed. Any utilisation beyond this is considered inappropriate. The manufacturer is not liable for any damages resulting therefrom. The TopVent commercial CUM is used for recirculation heating and cooling; it has been specially developed for application in hypermarkets and supermarkets. the unit is installed in the roof with the integrated roof frame. It takes in room air, heats or cools it and injects it back into the room via the Air-Injector. Thanks to its powerful and efficient air distribution the TopVent commercial CUM covers a large area. Therefore, in comparison with other systems, fewer units are needed to achieve the required environment. As the units are installed in the roof, they do not protrude far into the room and maintenance works are carried out from roof level, without disruption of business. 2.1 Unit construction The TopVent commercial CUM consists of the following components: Roof hood for recirculation (with inspection door) Roof frame Heating / cooling section (with fan, heat exchanger and built-in condensate separator) Automatically adjustable vortex air distributor Air-Injector To avoid condensation on the outer surface the roof hood and the heating / cooling section are insulated. The components are bolted together and can be dismantled, even after installation. The units are not suitable for use in explosive atmospheres, in high humidity areas or in rooms with a high dust load. 1.3 Hazards Despite all of the preventive measures that have been taken, there are certain hazards, which may not be obvious, e.g.: Danger when working on the electrical system Items (e.g. tools) can drop down when work is being done on the TopVent unit Malfunctions due to defective parts Danger from hot water when working on the heating system Roof hood for recirculation Roof frame Heating / cooling section Air-Injector Fig. F2 1: TopVent commercial CUM unit components 84

87 TopVent commercial CUM Function and Construction Casing: consisting of corrosion-resistant Aluzinc sheet steel Fan: axial fan with low energy consumption, quiet and maintenance-free Heat exchanger: LPHW / chilled water coil consisting of copper tubes with aluminium fins Condensate separator: with condensate drain connection Terminal box: with isolation switch, easily accessible behind the inspection door Air-Injector: patented, automatically adjustable vortex air distributor for draught-free air distribution over a large area Roof hood: insulated, easily removable with four hand grips Roof frame: made of sheet steel F Fig. F2 2: Construction of TopVent commercial CUM 2.2 Air distribution with the Air-Injector The patented air distributor called the Air-Injector is the core element. Its controllable vane arrangement allows continuous adjustment of the air discharge angle. The setting depends on the air flow rate ( fan speed), the mounting height and the temperature difference between supply air and room air. Thus the air is injected into the room either vertically downwards, conically or horizontally, ensuring that a large floor area is reached with each TopVent commercial CUM no draughts occur in the occupied area temperature stratification in the room is reduced and thus energy is saved. 85

88 TopVent commercial CUM Technical Data 3 Technical data Unit type Fan speed RPM (nominal) min -1 Nominal air flow rate m³ / h Floor area reached 1) max. m² Power consumption (at 400 V / 50 Hz) kw Current consumption (at 400 V / 50 Hz) A CUM-9 I ) Mounting height H max = 11 m up to 30 K temperature difference supply air - room air Table F3 1: Technical data of TopVent commercial CUM Unit type reference Unit type TopVent commercial CUM Unit size Size 9 Electrical connection D4 = DigiNet design KK = Terminal box design CUM 9 / D4 Unit type Fan speed Sound pressure level (5 m distance) 1) Total sound power level Octave sound power level 1) with hemispherical radiation in a room with little reflection db(a) db(a) 63 Hz db 125 Hz db 250 Hz db 500 Hz db 1000 Hz db 2000 Hz db 4000 Hz db 8000 Hz db CUM-9 I Table F3 2: Unit type reference Table F3 3: Sound level of TopVent commercial CUM 86

89 TopVent commercial CUM Technical Data Air inlet temperature 1) LPHW Unit type C 10 C Q t S H max m W p W kw C m l / h kpa 15 C Q t S H max m W p W kw C m l / h kpa 20 C Q t S H max m W p W kw C m l / h kpa 90 / 70 CUM-9 I 80 / 60 CUM-9 I 70 / 50 CUM-9 I / 40 CUM-9 I 82 / 71 CUM-9 I F Operating conditions not allowed because the maximum supply air temperature of 60 C is exceeded. Legend: Q = Heat output t S = Supply air temperature H max = Maximum mounting height m W = Water flow rate p W = Water pressure drop Table F3 4: Heat outputs of TopVent commercial CUM 87

90 TopVent commercial CUM Technical Data Cooling medium temp. t 1) ai rh Unit type C % 6 / 12 C Q tot Q sen t S m C m W p W kw kw C kg / h l / h kpa 8 / 14 C Q tot Q sen t S m C m W p W kw kw C kg / h l / h kpa 10 / 16 C Q tot Q sen t S m C m W p W kw kw C kg / h l / h kpa CUM-9 I 50 CUM-9 I 70 CUM-9 I CUM-9 I 50 CUM-9 I 70 CUM-9 I CUM-9 I 50 CUM-9 I 70 CUM-9 I Legend: t ai = Air inlet temperature rh = Air inlet humidity Q tot = Total cooling capacity Q sen = Sensible cooling capacity t S m C m W = Supply air temperature = Amount of condensate = Water flow rate p W = Water pressure drop Fig. F3 5: Cooling capacity of TopVent commercial CUM-9 88

91 TopVent commercial CUM Technical Data Rp 2" Rp 2" Rp ¾" F Roof frame: Unit type Weight Water content of coil kg l CUM Fig. F3 6: Dimensions and weights of TopVent commercial CUM Maximum operating pressure 800 kpa Maximum heating medium temperature 120 C Maximum supply air temperature 60 C Maximum ambient temperature 40 C Maximum amount of condensate 90 kg Minimum air flow rate m³ / h Table F3 7: Application limits of TopVent commercial CUM 89

92 TopVent commercial CUM Technical Data W X Y Unit type Fan speed Wall distance W min. m max. m Unit distance X min. m (centre to centre) max. m Mounting height Y min. m CUM-9 I Table F3 8: Minimum and maximum distances 90

93 TopVent commercial CUM Technical Data CUM-9 speed CUM-9 speed I 100 Pressure drop increase in Pa Example: An additional pressure drop of 38 Pa at 7800 m³/h results in a new air flow rate of 7190 m³/h. F Air flow rate in m³ / h Diagram F3 1: Air flow rate for TopVent commercial CUM-9 with additional pressure drop 91

94 TopVent commercial CUM Options 4 Options A wide range of accessories allows customisation of TopVent commercial CUM for each individual project. For a detailed description of all optional components please refer to part K 'Options' of this handbook. Paint finish Actuator for Air-Injector Flat filter box Acoustic cowl Insulation Condensate pump Hydraulic assembly In the Hoval standard colours red / orange (for free) or in any desired colour (extra charge) For adjustment of the Air-Injectors when using a non-hoval control system (for Hoval control equipment see section 5 'Control systems') For filtering recirculated air For lowering the noise level in the room (reduced noise radiation from the Air-Injector) Prevents condensation forming on the outer surfaces of the Air-Injector For condensate drainage through waste water pipes under the ceiling or onto the roof Prefabricated hydraulic assembly for diverting system Table F4 1: Options available with TopVent CUM 92

95 TopVent commercial CUM Control Systems 5 Control systems For TopVent commercial CUM, specially developed and optimised components for room temperature and air distribution control are available from Hoval. For a detailed description of these components please refer to part L 'Control systems' of this handbook. 5.1 Integrated system DigiNet (detailed description on request) Ideally, TopVent commercial CUM are controlled by DigiNet. This is an integrated system that has been specially developed for Hoval indoor climate systems. It controls room temperature as well as air distribution in fully automatic operation. For control by DigiNet, a DigiUnit terminal box is installed in the TopVent commercial CUM (instead of the standard terminal box). Table F5 1: Integrated control system for TopVent commercial CUM F 5.2 Room temperature control TempTronic This is a programmable, electronic temperature controller allowing fully automatic operation. Its control algorithm with fuzzy logic ensures smallest room temperature deviations from setpoints and minimises energy consumption. Table F5 2: Room temperature control systems for TopVent commercial CUM 5.3 Air distribution control Automatic control with the VarioTronic The VarioTronic is an electronic controller for the Air-Injector. It adjusts air distribution for changing operating conditions (fan speed, temperature difference between supply air and room air) and works independently of room temperature control. Manual control by means of potentiometer and actuator Where operating conditions change rarely or comfort requirements are not so high, air distribution may be controlled manually by means of a potentiometer. Fixed adjustment Where the basic conditions remain unchanged (constant supply air temperature, constant air flow rate), air distribution can be manually fixed at commissioning. Table F5 3: Air distribution control systems for TopVent commercial CUM 93

96 TopVent commercial CUM System Design 6 System design Example Usually, the primary function of TopVent commercial CUM is cooling; for this reason the design process is described for this function. The design for heating can be made in a similar way to the example in part B 'TopVent DHV'. Collect basic data Space dimensions (floor plan) Mounting height (= distance from floor to underside of the TopVent unit) Required cooling capacity Desired room conditions Cooling medium temperature (flow / return) Comfort requirements (acoustic) Space dimensions...40 m x 90 m Mounting height...7 m Required cooling capacity kw Desired room conditions...28 C / 30 % Cooling medium temperature... 6 / 12 C Comfort requirements...standard Comfort requirements (acoustic) According to acoustic requirements define the fan speed: Low sound level low fan speed (speed I) Normal sound level high fan speed (speed ) In this project the acoustic requirements are 'standard', hence use the high fan speed (speed ) for design calculations. Mounting height With the minimum mounting height (table F3-8) check which units can be used. According to table F3-8 the minimum mounting height is: CUM m Consequently, all sizes can be used in this project with a mounting height of 7 m. Minimum and maximum number of units For determining the minimum number of units three criteria must be fulfilled: a) Minimum number relating to floor area Table F3-1 indicates the maximum floor area that can be reached with TopVent commercial CUM units. With these values and the given floor area the minimum number of units can be determined for each unit size and coil type. b) Minimum number relating to space dimensions (length x width) Depending on space dimensions, a certain minimum number of units are required in the length and in the width. This can be calculated from the maximum distances between units and to the wall (see table F3-8). Calculate the minimum numbers according to a), b) and c) for each unit type and enter them in a table. Then take the highest value as minimum number of units d). Calculate the maximum possible number according to e) and enter the values in the table. 94

97 TopVent commercial CUM System Design c) Minimum number relating to cooling capacity The minimum number for each unit size and coil type can be calculated from the required total cooling capacity (table F3-5). Please note that only the sensible cooling capacity Q sen is available for cooling of the space while the total capacity Q tot must be used for sizing the chiller. Type a) b) c) d) e) CUM d) Effective minimum number of units The highest value of the foregoing calculations a), b) and c) is the effective minimum number of units that should be installed. e) Maximum number of units The minimum number determined under d) normally corresponds to the solution selected in practice as it incurs the lowest costs. Yet if comfort requirements are particularly high more units may be provided. The maximum number of units is theoretically determined from the total floor area divided by the minimum floor area reached per unit X 2 (X = minimum distance between units, see table F3-8). F Definite number of units According to space dimensions, comfort requirements and costs, select the optimum solution from the remaining alternatives. Due to the space dimensions, comfort requirements and the investment made available the solution with 8 TopVent commercial CUM-9 is selected. Automatic control Ideally, TopVent commercial CUM are controlled by DigiNet; this system is perfectly suited to control all unit functions. If a TempTronic is used for room temperature control, check maximum switching power. The maximum floor area reached depends on the one hand on local conditions and on the other hand on the quality of air distribution. Due to the complexity of air flow mechanisms in large rooms the design quantities can only partly be mathematically described. The quality of the air distributor affects the supplied energy made available in the occupied area as a function of the air flow rate, the temperature difference between supply air and room air and the mounting height. Tests on the test rig and the experience of numerous applications show that with the Air-Injector this conversion of energy is effected with considerably higher efficiency than with other air distributors usually employed in recirculation units. This higher quality leads to lower running costs as well as to a larger floor area reached and thus fewer units are needed. To facilitate the design process concerning the floor area reached we have decided to dispense with complicated formulas and diagrams. However, it is important to keep to the limiting values and to make sure that the primary and secondary air flow can spread unhindered. If the given limits are exceeded in your application please seek Hoval advice. 95

98 TopVent commercial CUM Transport and Installation 7 Transport and installation Transport and installation to be carried out by experts only! A lifting appliance is required for transportation and installation of the units! Do not tilt or lay the unit on its side! 7.1 Installation The TopVent commercial CUM comes completely assembled with roof frame and roof hood. Installation is carried out from roof level: Hook lifting gear into the four lugs at the side of the unit. Lift the unit and turn the coil connections in the required position. Place the unit onto the roof opening and secure it. Insulate and seal the roof frame from the outside. The roof frame support must be level and horizontal. Alternatively, the unit can be installed in two steps: First install the roof frame with the roof hood, then take off the roof hood and insert the ventilation unit from above. 7.2 Hydraulic installation Hydraulic installation to be carried out by experts only! For easy and quick hydraulic installation use the options 'Hydraulic assembly' and 'Condensate pump'! Combine units working under equal operating conditions (room temperature, heat gain, operating time, etc.) into one control zone. Low or medium pressure hot water up to 120 C can be used as a heating medium. To save energy, the distributor can be pre-calibrated; it should, however, be ensured that the heat requirement of each heater battery can always be met. Connect the individual heating / cooling coils as shown in figure F7 1. Depending on local conditions, it should also be considered whether compensations for flow and return pipework are needed to balance the longitudinal expansion and / or flexible connections for the units. The heat exchanger cannot take up any extra load, e.g. through the flow or return pipe. Adequately size the slope and cross section of the condensate drain to prevent a condensate backwash. Install a 200 mm trap. The individual units within a control zone must be hydraulically balanced to ensure even temperatures. Air vent Balancing valve Drain cocks Isolating valves Flow Return Condensate drain (with trap) 2-port valve Fig. F7 1: Heating / cooling coil connection 96

99 TopVent commercial CUM Transport and Installation 7.3 Electrical installation The electrical connections to the unit must be carried out by an electrical expert. Relevant regulations must be observed. The unit is delivered ready for use. Check that the local operating voltage, frequency and fusing are in accordance with the information on the nameplate. If any discrepancies occur the unit must not be connected! Check cable diameters when using long wiring runs. Electrical installation to be carried out according to the wiring diagram for the control equipment. Connection of the TopVent units to be carried out according to the wiring diagram. Connect thermal relays built into the motor; otherwise the motor is not protected against overheating. F Do not forget to install a main switch for the whole system (control, units). Several TopVent units can be connected in parallel. Thermal relays and isolation switches must be wired in series! The condensate separator only works with the fan running. Therefore, switch off the cooling pump together with the fan. For TopVent commercial CUM in DigiNet design, electrical installation by the installer only requires: Mains supply (3 x 400 VAC / 50 Hz) LON bus cable (2 x 0.5 mm² twisted, input and output) Plug connection between mixing valve and DigiUnit terminal box Actuator for Air- Injector Supply air sensor (option) Room air sensor (option) Cooling valve (option) Filter pressure switch Condensate pump control (option) For TopVent commercial CUM in terminal box design the following electrical connections are to be provided by the installer: Mains supply (3 x 400 VAC / 50 Hz) Thermal relay Supply air sensor (option) Filter pressure switch Actuator for Air-Injector (option) Condensate pump (option) Plug connection between mixing valve and terminal box (option) Isolation switch Supply air fan 2-speed Thermal relay Condensate pump (option) Fig. F7 2: Wiring diagram for TopVent commercial CUM in terminal box design 97

100 TopVent commercial CUM Specification Texts 8 Specification texts TopVent commercial CUM Roof unit for heating and cooling supermarkets Casing made of corrosion-resistant Aluzinc sheet steel, heating / cooling section insulated inside. Heat exchanger of copper tubes with aluminium fins. Headers are made of steel. A frost stat is included. A condensate separator with drain connection is installed. Fan unit consisting of a 2-speed three-phase motor of the external-rotor type with rigid sickle-shaped aluminium blade impeller, maintenance-free and quiet at high efficiency. Motor protection with built-in thermal relays. Protection rating IP54. Vortex air distributor with concentric outlet nozzle, twelve adjustable guide vanes and integrated sound attenuation cowl. Supporting roof frame made of galvanised sheet steel, with black paint-finish and four lifting lugs. Roof hood made of Aluzinc sheet steel, with internal insulation and inspection door. Terminal box built into the roof hood, easily accessible behind the inspection door. The following components are installed: Isolation switch Connection terminals The unit components are completely wired. Variant: DigiNet design DigiUnit terminal box as part of the digital control system Hoval DigiNet. The DigiUnit terminal box houses the highvoltage section with Isolation switch Motor protection per fan speed Fuse for electronics Transformer Relay for emergency operation Connection terminals and the DigiUnit controller. This controls the individual unit, including air distribution, and is to be linked to the other components of the Hoval DigiNet via LON bus. A supply air sensor is installed in the vortex air distributor. The unit components are completely wired. Technical data Fan speed I Nominal air flow rate m³ / h Floor area reached m² Mounting height m Nominal cooling capacity kw with chilled water C air inlet temperature C and air inlet humidity % Nominal heating capacity kw with LPHW C and air inlet temperature C Power consumption kw Current consumption A Voltage 400 V / 50 Hz CUM-9 Standard paint finish SL In the Hoval colours red (RAL 3000) and orange (RAL 2008). Special paint finish AL In RAL colour No. Actuator for Air-Injector VT-A Complete with cable, for adjustment of the Air-Injector when using a non-hoval control system. Flat filter box FFK With four V-cell filters class G4 (to DIN EN 779). Filter pressure switch FUDHV For supervision of filter cleaning intervals. Acoustic cowl AHD Consisting of a sound attenuation cowl with bigger volume and a faceplate with sound-insulation lining, insertion attenuation 4 db(a). Insulation ID Of the Air-Injector. Condensate pump KP Consisting of a centrifugal pump, collecting tray and flexible hose, delivery output max. 80 l / h at 3 m delivery height. Hydraulic assembly HG8D-UM Consisting of mixing valve with 75 s actuation time, balancing valve STAD, ball valve, automatic air vent, drain cock and screw joints for coil connection and distribution circuit. 98

101 TopVent commercial CUM Specification Texts Room temperature control with the TempTronic Electronic controller with 2-speed 2-point control, fuzzy logic, clock with automatic summer / winter changeover and holiday programme. TempTronic SHK, controller for heating and cooling operation, built as wall unit in a plastic casing with transparent lid, room air sensor included TempTronic SHK-S, controller for heating and cooling operation, built for installation in a control panel (without casing, transformer, contactors and fuses), room air sensor included Three additional room air sensors for averaging TS1M Cylinder lock ZS for TempTronic wall unit Automatic air distribution control with the VarioTronic Electronic controller with well-proven control algorithm for changing operating conditions. VarioTronic VT-W, control module built as wall unit, in a plastic casing with transparent lid VarioTronic VT-S, control module for installation in a control panel (without casing, transformer, contactor and fuses) Cylinder lock ZS for VarioTronic wall unit Actuator VT-AK with cable, plug, supply air sensor and room air sensor Actuator VT-AS with cable and plug Separate room air sensor TS1 F Manual air distribution control with the potentiometer Manual control by means of a potentiometer and actuator with a range of 0 to 50 for adjustment of the air discharge angle between vertical and horizontal. Potentiometer wall unit PMS-W Potentiometer for installation in a control panel PMS-S Actuator VT-AS with cable and plug Transformer TA for maximum 7 actuators 99

102 100

103 TopVent MH G Supply air unit for ventilating and heating high spaces 1 Intended use Function and construction Technical Data Options Control systems System design Transport and installation Specification texts 118

104 TopVent MH Intended Use 1 Intended use 2 Function and construction TopVent MH is used for ventilating and heating high spaces with variable fresh air supply. Correct usage also entails adherence to the manufacturer's conditions for installation, initial start-up, operation and maintenance (operating instructions) as well as consideration of possible malfunctions and of hazards. 1.1 User group TopVent units are only to be installed, operated and serviced by authorised and trained specialists who are familiar with and have been instructed on the hazards. The operating instructions are for English-speaking works engineers and technicians as well as specialists in building, heating and ventilation technology. 1.2 Modes of operation TopVent MH units have the following operating modes: Fresh air, mixed air or recirculation operation at low fan speed ( % fresh air) Fresh air, mixed air or recirculation operation at high fan speed ( % fresh air) Standby Off The application limits given in the 'Technical Data' section must be observed. Any utilisation beyond this is considered inappropriate. The manufacturer is not liable for any damages resulting therefrom. The TopVent MH is used for ventilating and heating in fresh air, mixed air or recirculation operation; it has been specially developed for application in high spaces. The unit is installed under the ceiling and connected to a fresh air duct. Depending on the damper position it takes in fresh air and / or room air, heats it by means of the heater battery and injects it back into the room via the Air-Injector. Thanks to its powerful and efficient air distribution the TopVent MH covers a large area. Therefore, in comparison with other systems, fewer units are needed to achieve the required environment. Three unit sizes, 2-speed fans, different heater battery types and a wide variety of accessories provide a tailored solution for each application. Furthermore, special batteries (steam, electrical heating) are also available. 2.1 Unit construction The TopVent MH consists of the following components: Mixed air box (with fresh air / recirculation dampers) Filter box (with two bag filters class G4) Heating section (with fan and heater battery) Automatically adjustable vortex air distributor Air-Injector The components are bolted together and can be dismantled even after installation. The units are not suitable for use in explosive atmospheres, in high humidity areas or in rooms with a high dust load. 1.3 Hazards Despite all of the preventive measures that have been taken, there are certain hazards, which may not be obvious, e.g.: Danger when working on the electrical system Items (e.g. tools) can drop down when work is being done on the TopVent unit Malfunctions due to defective parts Danger from hot water when working on the heating system Mixed air box Filter box Heating section Air-Injector Fig. G2 1: TopVent MH unit components 102

105 TopVent MH Function and Construction Casing: consisting of corrosion-resistant Aluzinc sheet steel Fan: axial fan with low energy consumption, quiet and maintenance-free Heat exchanger: LPHW heater battery consisting of copper tubes with aluminium fins Frost stat: installed on the heat exchanger Terminal box Air-Injector: patented, automatically adjustable vortex air distributor for draught-free air distribution over a large area Filter box: easily accessible behind sliding door, with two bag filters class G4 and differential pressure switch for filter supervision Mixed air box: with fresh air and recirculation dampers made from aluminium extrusions with plastic gear wheels Fresh air duct with flexible connector (not included in Hoval delivery) G Fig. G2 2: Construction of TopVent MH 2.2 Air distribution with the Air-Injector The patented air distributor called the Air-Injector is the core element. Its controllable vane arrangement allows continuous adjustment of the air discharge angle. The setting depends on the air flow rate ( fan speed), the mounting height and the temperature difference between supply air and room air. Thus the air is injected into the room either vertically downwards, conically or horizontally, ensuring that a large floor area is reached with each TopVent MH unit no draughts occur in the occupied area temperature stratification in the room is reduced and thus energy is saved. 103

106 TopVent MH Technical Data 3 Technical Data Unit type Fan speed RPM (nominal) min -1 Nominal air flow rate m³ / h Floor area reached 1) max. m² Power consumption (at 400 V / 50 Hz) kw Current consumption (at 400 V / 50 Hz) A MH-6 / A I MH-6 / B I MH-6 / C I Unit type Fan speed RPM (nominal) min -1 Nominal air flow rate m³ / h Floor area reached 1) max. m² Power consumption (at 400 V / 50 Hz) kw Current consumption (at 400 V / 50 Hz) A MH-9 / A I MH-9 / B I MH-9 / C I Unit type Fan speed RPM (nominal) min -1 Nominal air flow rate m³ / h Floor area reached 1) max. m² Power consumption (at 400 V / 50 Hz) kw Current consumption (at 400 V / 50 Hz) A MH-10 / A I MH-10 / B I MH-10 / C I ) Mounting height H max = 9 m up to 30 K temperature difference supply air - room air Table G3 1: Technical data of TopVent MH Unit type reference Unit type TopVent MH Unit size 6, 9 or 10 Heat exchanger Coil type A, B or C MH 6 / A Unit type Fan speed Sound pressure level (5 m distance) 1) db(a) Total sound power level db(a) Octave sound power level 63 Hz db 125 Hz db 250 Hz db 500 Hz db 1000 Hz db 2000 Hz db 4000 Hz db 8000 Hz db MH-6 I MH-9 I MH-10 I ) with hemispherical radiation in a room with little reflection Table G3 2: Unit type reference Table G3 3: Sound level of TopVent MH 104

107 TopVent MH Technical Data MH-6 Air inlet temperature 1) LPHW Unit type C 90 / 70 MH-6 / A I MH-6 / B I MH-6 / C I 10 C Q t S H max m W p W kw C m l / h kpa C Q t S H max m W p W kw C m l / h kpa C Q t S H max m W p W kw C m l / h kpa / 60 MH-6 / A I MH-6 / B I MH-6 / C I / 50 MH-6 / A I MH-6 / B I MH-6 / C I G 60 / 40 MH-6 / A I MH-6 / B I MH-6 / C I / 71 MH-6 / A I MH-6 / B I MH-6 / C I ) The air inlet temperatures (10/ 15 / 20 C) correspond to room air temperature. The given heat outputs relate to a fresh air rate of 20 % (at -10 C); i.e. the mixed temperatures at the coil inlet are 6 / 10 / 14 C. Operating conditions not allowed because the maximum supply air temperature of 60 C is exceeded. Legend: Q = Heat output t S = Supply air temperature H max = Maximum mounting height m W = Water flow rate p W = Water pressure drop Table G3 4: Heat outputs of TopVent MH-6 105

108 TopVent MH Technical Data MH-9 Air inlet temperature 1) LPHW Unit type C 90 / 70 MH-9 / A I MH-9 / B I MH-9 / C I 10 C Q t S H max m W p W kw C m l / h kpa C Q t S H max m W p W kw C m l / h kpa C Q t S H max m W p W kw C m l / h kpa / 60 MH-9 / A I MH-9 / B I MH-9 / C I / 50 MH-9 / A I MH-9 / B I MH-9 / C I / 40 MH-9 / A I MH-9 / B I MH-9 / C I / 71 MH-9 / A I MH-9 / B I MH-9 / C I ) The air inlet temperatures (10/ 15 / 20 C) correspond to room air temperature. The given heat outputs relate to a fresh air rate of 20 % (at -10 C); i.e. the mixed temperatures at the coil inlet are 6 / 10 / 14 C. Operating conditions not allowed because the maximum supply air temperature of 60 C is exceeded. Legend: Q = Heat output t S = Supply air temperature H max = Maximum mounting height m W = Water flow rate p W = Water pressure drop Table G3 5: Heat outputs of TopVent MH-9 106

109 TopVent MH Technical Data MH-10 Air inlet temperature 1) LPHW Unit type C 90 / 70 MH-10 / A I MH-10 / B I MH-10 / C I 80 / 60 MH-10 / A I MH-10 / B I MH-10 / C I 10 C Q t S H max m W p W kw C m l / h kpa C Q t S H max m W p W kw C m l / h kpa C Q t S H max m W p W kw C m l / h kpa / 50 MH-10 / A I MH-10 / B I MH-10 / C I G 60 / 40 MH-10 / A I MH-10 / B I MH-10 / C I / 71 MH-10 / A I MH-10 / B I MH-10 / C I ) The air inlet temperatures (10/ 15 / 20 C) correspond to room air temperature. The given heat outputs relate to a fresh air rate of 20 % (at -10 C); i.e. the mixed temperatures at the coil inlet are 6 / 10 / 14 C. Operating conditions not allowed because the maximum supply air temperature of 60 C is exceeded. Legend: Q = Heat output t S = Supply air temperature H max = Maximum mounting height m W = Water flow rate p W = Water pressure drop Table G3 6: Heat outputs of TopVent MH

110 TopVent MH Technical Data Return Flow Unit type A mm B mm C mm D mm E mm F mm G mm H mm J " L mm O x P mm R mm T mm Weight kg Water content Type heater battery l MH Rp 1¼ (female) x A B C MH Rp 1½ (female) x A B C MH Rp 1½ (female) x A B C Table G3 7: Dimensions and weights of TopVent MH Maximum operating pressure 800 kpa Maximum heating medium temperature 120 C Maximum supply air temperature 60 C Maximum ambient temperature 40 C Table G3 8: Application limits of TopVent MH 108

111 TopVent MH Technical Data W X Y Unit type Fan speed Wall distance W min. m max. m Unit distance X min. m (centre to centre) max. m Mounting height Y min. m I MH-6 / A MH-6 / B I MH-6 / C I G Unit type Fan speed Wall distance W min. m max. m Unit distance X min. m (centre to centre) max. m Mounting height Y min. m MH-9 / A I MH-9 / B I MH-9 / C I Unit type Fan speed Wall distance W min. m max. m Unit distance X min. m (centre to centre) max. m Mounting height Y min. m MH-10 / A I MH-10 / B I MH-10 / C I Table G3 9: Minimum and maximum distances 109

112 TopVent MH Technical Data 120 Pressure drop increase in Pa Example: An additional pressure drop of 53 Pa at 4640 m³/h results in a new air flow rate of 3900 m³/h. MH-6 / A MH-6 / B MH-6 / C MH-6 / A MH-6 / B MH-6 / C speed speed speed speed I speed I speed I Air flow rate in m³ / h Diagram G3 1: Air flow rate for TopVent MH-6 with additional pressure drop Pressure drop increase in Pa MH-9 / A MH-9 / B MH-9 / C MH-9 / A MH-9 / B MH-9 / C speed speed speed speed I speed I speed I Air flow rate in m³ / h Diagram G3 2: Air flow rate for TopVent MH-9 with additional pressure drop 110

113 TopVent MH Technical Data Pressure drop increase in Pa MH-10 / A MH-10 / B MH-10 / C MH-10 / A MH-10 / B MH-10 / C speed speed speed speed I speed I speed I 10 G Air flow rate in m³ / h Diagram G3 3: Air flow rate for TopVent MH-10 with additional pressure drop 111

114 TopVent MH Options 4 Options A wide range of accessories allows customisation of TopVent MH units for each individual project. For a detailed description of all optional components please refer to part K 'Options' of this handbook. Paint finish Suspension set Isolation switch Actuator for Air-Injector Actuator for mixed air box Acoustic cowl Insulation In the Hoval standard colours red / orange (for free) or in any desired colour (extra charge) For fastening the unit to the ceiling External on / off mains switch For adjustment of the Air-Injectors when using a non-hoval control system (for Hoval control equipment see section 5 'Control systems') For adjustment of the fresh air and recirculation dampers when using a non-hoval control system (for Hoval control equipment see section 5 'Control systems') For lowering the noise level in the room (reduced noise radiation from the Air-Injector) Prevents condensation forming on the outer surfaces of the mixed air box, the filter box and the Air-Injector Table G4 1: Options available with TopVent MH 112

115 TopVent MH Control Systems 5 Control systems For TopVent MH units, specially developed and optimised components for room temperature, air distribution and fresh air rate control are available from Hoval. For a detailed description of these components please refer to part L 'Control systems' of this handbook. 5.1 Integrated system DigiNet (detailed description on request) Ideally, TopVent MH units are controlled by DigiNet. This is an integrated system that has been specially developed for Hoval indoor climate systems. It controls room temperature as well as air distribution and constantly optimises the fresh air rate (i.e. just as much fresh air is taken in as necessary to maintain the room temperature without additional heating). Table G5 1: Integrated control system for TopVent MH 5.2 Room temperature and fresh air rate control Basic control Basic control is a low-cost control system for TopVent MH units. It meets all requirements on modern recirculation heating, however, automatic control of the fresh air rate does not take place. Table G5 2: Room temperature and fresh air rate control systems for TopVent MH G 5.3 Air distribution control Automatic control with the VarioTronic The VarioTronic is an electronic controller for the Air-Injector. It adjusts air distribution for changing operating conditions (fan speed, temperature difference between supply air and room air) and works independently of room temperature control. Manual control by means of potentiometer and actuator Where operating conditions change rarely or comfort requirements are not so high, air distribution may be controlled manually by means of a potentiometer. Fixed adjustment Where the basic conditions remain unchanged (constant supply air temperature, constant air flow rate), air distribution can be manually fixed at commissioning. Table G5 3: Air distribution control systems for TopVent MH 113

116 TopVent MH System Design 6 System design Example Collect basic data Space dimensions (floor plan) Mounting height (= distance from floor to underside of the TopVent unit) Required heat output Desired room temperature Heating medium temperature (flow / return) Comfort requirements (acoustic) Fresh air temperature Minimum fresh air flow rate (The fresh air rate can be adjusted as desired between 0 % and 100 %; for an efficient use of energy the design calculation is to be based on a minimum value.) Space dimensions...60 m x 60 m Mounting height...8 m Required heat output kw Desired room temperature...20 C Heating medium temperature / 60 C Comfort requirements...standard Fresh air temperature C Minimum fresh air flow rate m³ / h Comfort requirements (acoustic) According to acoustic requirements define the fan speed: Low sound level low fan speed (speed I) Normal sound level high fan speed (speed ) In this project the acoustic requirements are 'standard', hence use the high fan speed (speed ) for design calculations. Mounting height With the minimum mounting height (table G3-9) check which units can be used. Check maximum mounting height according to heating medium temperature and inlet air temperature (= room temperature) (tables G3-4, G3-5 and G3-6). Eliminate units that cannot be used. According to table G3-9 the minimum mounting heights are: MH m MH-9, MH m Consequently, all sizes can be used in this project with a mounting height of 8 m. According to tables G3-4, G3-5 and G3-6 and the given conditions (heating medium temperature 80 / 60 C, inlet air temperature 20 C) the following unit types cannot be employed due to the maximum mounting height: MH-6 / C... H max = 7.3 m Minimum and maximum number of units For determining the minimum number of units three criteria must be fulfilled: a) Minimum number relating to floor area Table G3-1 indicates the maximum floor area that can be reached with TopVent MH units. With these values and the given floor area the minimum number of units can be determined for each unit size and coil type. b) Minimum number relating to space dimensions (length x width) Depending on space dimensions, a certain minimum number of units are required in the length and in the width. This can be calculated from the maximum distances between units and to the wall (see table G3-9). Calculate the minimum numbers according to a), b) and c) for each unit type and enter them in a table. Then take the highest value as minimum number of units d). Calculate the maximum possible number according to e) and enter the values in the table. 114

117 TopVent MH System Design c) Minimum number relating to heat output The minimum number for each unit size and coil type can be calculated from the required total heat output (tables G3-4, G3-5 and G3-6). d) Effective minimum number of units The highest value of the foregoing calculations a), b) and c) is the effective minimum number of units that should be installed. e) Maximum number of units The minimum number determined under d) normally corresponds to the solution selected in practice as it incurs the lowest costs. Yet if comfort requirements are particularly high more units may be provided. The maximum number of units is theoretically determined from the total floor area divided by the minimum floor area reached per unit X 2 (X = minimum distance between units, see table G3-9). Type a) b) c) d) e) MH-6 / A MH-6 / B MH-6 / C no solution MH-9 / A MH-9 / B MH-9 / C MH-10 / A MH-10 / B MH-10 / C Definite number of units According to space dimensions, comfort requirements and costs, select the optimum solution from the remaining alternatives. Fresh air rate Calculate the minimum fresh air rate from the air flow rate of the selected units (see table G3-1) and the required minimum fresh air flow rate. Due to the space dimensions, comfort requirements and the investment made available the solution with 9 TopVent MH-6 / A is selected. Total air flow rate: 9 x 4600 m³ / h = m³ / h Minimum fresh air flow rate: 8300 m³ / h Minimum fresh air rate: 20 % G Automatic control Group units working under equal operating conditions (room temperature, heat demand, operating times) into control zones. Check maximum switching power of the controller. Check if, in view of operating conditions, automatic control of the air distributor with the VarioTronic is worthwhile. The low-cost solution is 1 TempTronic controller for all 9 units: Switching power = 9 x 0.69 kw < 6.5 kw The maximum floor area reached depends on the one hand on local conditions and on the other hand on the quality of air distribution. Due to the complexity of air flow mechanisms in large rooms the design quantities can only partly be mathematically described. The quality of the air distributor affects the supplied energy made available in the occupied area as a function of the air flow rate, the temperature difference between supply air and room air and the mounting height. Tests on the test rig and the experience of numerous applications show that with the Air-Injector this conversion of energy is effected with considerably higher efficiency than with other air distributors usually employed in recirculation units. This higher quality leads to lower running costs as well as to a larger floor area reached and thus fewer units are needed. To facilitate the design process concerning the floor area reached we have decided to dispense with complicated formulas and diagrams. However, it is important to keep to the limiting values and to make sure that the primary and secondary air flow can spread unhindered. If the given limits are exceeded in your application please seek Hoval advice. 115

118 TopVent MH Transport and Installation 7 Transport and installation Transport and installation to be carried out by experts only! A lifting appliance is required for transportation and installation of the units! Do not tilt or lay the unit on its side! 7.1 Installation For fastening to the ceiling, the unit is equipped with four M10 captive nuts with hexagon head screws and washers as standard. With these and the height adjustable suspension set (option) the unit is easily fixed to the ceiling. The captive nuts are only designed for the unit's own weight. Do not put on any additional loads! The captive nuts cannot sustain a bending moment; therefore do not use eyebolts! Installation by means of steel flat, slotted steel flat, angle or steel wire is also possible, but the following has to be considered: 7.2 Hydraulic installation Hydraulic installation to be carried out by experts only! Combine units working under equal operating conditions (room temperature, heat gain, operating time, etc.) into one control zone. Low or medium pressure hot water up to 120 C can be used as a heating medium. To save energy, the distributor can be pre-calibrated; it should, however, be ensured that the heat requirement of each heater battery can always be met. Connect the individual heating coils as shown in figure G7 2. Depending on local conditions, it should also be considered whether compensations for flow and return pipework are needed to balance the longitudinal expansion and / or flexible connections for the units. The heat exchanger cannot take up any extra load, e.g. through the flow or return pipe. The individual units within a control zone must be hydraulically balanced to ensure even temperatures. Non-vertical suspensions are permissible up to a maximum angle of 45. The unit must be installed with its top face horizontal (level)! For connection to the fresh air duct it is advisable to install a flexible connector. max. 45 max. 45 Air vent Balancing valve Drain cocks Isolating valves Flow Return Fig. G7 1: Suspension of TopVent MH Fig. G7 2: Heating coil connection 116

119 TopVent MH Transport and Installation 7.3 Electrical installation The electrical connections to the unit must be carried out by an electrical expert. Relevant regulations must be observed. The unit is delivered ready for use. Check that the local operating voltage, frequency and fusing are in accordance with the information on the nameplate. If any discrepancies occur the unit must not be connected! Check cable diameters when using long wiring runs. Electrical installation to be carried out according to the wiring diagram for the control equipment. Connection of the TopVent units to be carried out according to the wiring diagram. Connect thermal relays built into the motor; otherwise the motor is not protected against overheating. Do not forget to install a main switch for the whole system (control, units). Several TopVent units can be connected in parallel. G Thermal relays and isolation switches must be wired in series! Isolation switch (optional) Low fan speed (Y connection) Filter pressure switch Actuator for mixed air box (optional) Switch position L Thermal relay Fan (wiring by the installer) High fan speed ( connection) (wiring by the installer) Fig. G7 3: Wiring diagram for TopVent MH 117

120 TopVent MH Specification Texts 8 Specification texts TopVent MH Supply air unit for ventilating and heating high spaces Casing made of corrosion-resistant Aluzinc sheet steel. For fastening to the ceiling, the unit is equipped with four M10 captive nuts with hexagon head screws and washers as standard. Heat exchanger of copper tubes with aluminium fins. Headers are made of steel. Fan unit consisting of a 2-speed three-phase motor of the external-rotor type with rigid sickle-shaped aluminium blade impeller, maintenance-free and quiet at high efficiency. Motor protection with built-in thermal relays. Protection rating IP54. Filter box with two bag filters class G4, incl. differential pressure switch for supervision of filter cleaning intervals. Mixed air box made of Aluzinc sheet steel with fresh air / recirculation dampers. Terminal box built into the casing sidewall for connection of mains supply and accessories. Vortex air distributor with concentric outlet nozzle, twelve adjustable guide vanes and integrated sound attenuation cowl. Suspension set AHS For fastening the units to the ceiling, consisting of 4 pairs of Aluzinc steel U sections, height adjustable up to 1300 mm. Paint finish as for the unit. Isolation switch RS In the terminal box of the TopVent unit. Actuator for Air-Injector VT-A Complete with cable, for adjustment of the Air-Injector when using a non-hoval control system. Actuator for mixed air box MLK-A With cable, for adjustment of the fresh air and recirculation dampers when using a non-hoval control system Acoustic cowl AHD Consisting of a sound attenuation cowl with bigger volume and a faceplate with sound-insulation lining, insertion attenuation 4 db(a). Insulation ID of the Air-Injector of the filter box of the mixed air box Technical data Fan speed I Nominal air flow rate m³ / h Floor area reached m² Mounting height m Nominal heating capacity kw with LPHW C and air inlet temperature C Power consumption kw Current consumption A Voltage 400 V / 50 Hz MH-6 / A MH-6 / B MH-6 / C MH-9 / A MH-9 / B MH-9 / C MH-10 / A MH-10 / B MH-10 / C Standard paint finish SL In the Hoval colours red (RAL 3000) and orange (RAL 2008). Special paint finish AL In RAL colour No. 118

121 TopVent MH Specification Texts Room temperature and fresh air rate control with the basic control Electronic controller with 2-speed 2-point control, fuzzy logic, clock with automatic summer / winter changeover and holiday programme, combined with manual control by means of potentiometer and actuator for adjustment of the fresh air rate between 0 % and 100 %. TempTronic SHK, built as wall unit in a plastic casing with transparent lid, room air sensor included Three additional room air sensors for averaging TS1M Cylinder lock ZS for TempTronic wall unit Potentiometer wall unit PMS-W Transformer TA for maximum 7 actuators Automatic air distribution control with the VarioTronic Electronic controller with well-proven control algorithm for changing operating conditions. VarioTronic VT-W, control module built as wall unit, in a plastic casing with transparent lid VarioTronic VT-S, control module for installation in a control panel (without casing, transformer, contactor and fuses) Cylinder lock ZS for VarioTronic wall unit Actuator VT-AK with cable, plug, supply air sensor and room air sensor Actuator VT-AS with cable and plug Separate room air sensor TS1 G Manual air distribution control with the potentiometer Manual control by means of a potentiometer and actuator with a range of 0 to 50 for adjustment of the air discharge angle between vertical and horizontal. Potentiometer wall unit PMS-W Potentiometer for installation in a control panel PMS-S Actuator VT-AS with cable and plug Transformer TA for maximum 7 actuators 119

122 120

123 TopVent MK H Supply air unit for ventilating, heating and cooling high spaces 1 Intended use Construction and Function Technical data Options Control systems System design Transport and installation Specification texts 137

124 TopVent MK Intended Use 1 Intended use 2 Construction and Function TopVent MK is used for ventilating, heating and cooling high spaces with variable fresh air supply. Correct usage also entails adherence to the manufacturer's conditions for installation, initial start-up, operation and maintenance (operating instructions) as well as consideration of possible malfunctions and of hazards. 1.1 User group TopVent units are only to be installed, operated and serviced by authorised and trained specialists who are familiar with and have been instructed on the hazards. The operating instructions are for English-speaking works engineers and technicians as well as specialists in building, heating and ventilation technology. 1.2 Modes of operation TopVent MK units have the following operating modes: Fresh air, mixed air or recirculation operation at low fan speed ( % fresh air) Fresh air, mixed air or recirculation operation at high fan speed ( % fresh air) Standby Off The application limits given in the 'Technical Data' section must be observed. Any utilisation beyond this is considered inappropriate. The manufacturer is not liable for any damages resulting therefrom. The TopVent MK is used for ventilating, heating and cooling in fresh air, mixed air or recirculation modes; it has been specially developed for application in high spaces. The unit is installed under the ceiling and connected to a fresh air duct. Depending on the damper position it takes in fresh air and / or room air, heats or cools it and injects it back into the room via the Air-Injector. Thanks to its powerful and efficient air distribution the TopVent MK covers a large area. Therefore, in comparison with other systems, fewer units are needed to achieve the required environment. Two unit sizes, 2-speed fans, different coil types and a wide variety of accessories provide a tailored solution for each application. 2.1 Unit construction The TopVent MK consists of the following components: Mixed air box (with fresh air / recirculation dampers) Filter box (with two bag filters class G4) Heating / cooling section (with fan, heat exchanger and built-in condensate separator) Automatically adjustable vortex air distributor Air-Injector To avoid condensation on the outer surface the heating / cooling section is insulated. The components are bolted together and can be dismantled even after installation. The units are not suitable for use in explosive atmospheres, in high humidity areas or in rooms with a high dust load. 1.3 Hazards Despite all of the preventive measures that have been taken, there are certain hazards, which may not be obvious, e.g.: Danger when working on the electrical system Items (e.g. tools) can drop down when work is being done on the TopVent unit Malfunctions due to defective parts Danger from hot water when working on the heating system Mixed air box Filter box Heating / cooling section Air-Injector Fig. H2 1: TopVent MK unit components 122

125 TopVent MK Function and Construction Casing: consisting of corrosion-resistant Aluzinc sheet steel Fan: axial fan with low energy consumption, quiet and maintenance-free Heat exchanger: LPHW / chilled water heater battery consisting of copper tubes with aluminium fins Frost stat: installed on the heat exchanger Condensate separator: with condensate drain connection Terminal box Air-Injector: patented, automatically adjustable vortex air distributor for draught-free air distribution over a large area Filter box: easily accessible behind sliding door, with two bag filters class G4 and differential pressure switch for filter supervision Mixed air box: with fresh air and recirculation dampers made from aluminium extrusions with plastic gear wheels Fresh air duct with flexible connector (not included in Hoval delivery) H Fig. H2 2: Construction of TopVent MK 2.2 Air distribution with the Air-Injector The patented air distributor called the Air-Injector is the core element. Its controllable vane arrangement allows continuous adjustment of the air discharge angle. The setting depends on the air flow rate ( fan speed), the mounting height and the temperature difference between supply air and room air. Thus the air is injected into the room either vertically downwards, conically or horizontally, ensuring that a large floor area is reached with each TopVent MK unit no draughts occur in the occupied area temperature stratification in the room is reduced and thus energy is saved. 123

126 TopVent MK Technical Data 3 Technical data Unit type Fan speed RPM (nominal) min -1 Nominal air flow rate m³ / h Floor area reached 1) max. m² Power consumption (at 400 V / 50 Hz) kw Current consumption (at 400 V / 50 Hz) A MK-6 / C I ) Mounting height H max = 8 m up to 30 K temperature difference supply air - room air MK-9 / C I MK-9 / D I Table H3 1: Technical data of TopVent MK Unit type reference Unit type TopVent MK Unit size 6 or 9 Heat exchanger Coil type C or D MK 6 / C Unit type Fan speed Sound pressure level (5 m distance) Total sound power level Octave sound power level db(a) db(a) 63 Hz db 125 Hz db 250 Hz db 500 Hz db 1000 Hz db 2000 Hz db 4000 Hz db 8000 Hz db MK-6 I MK-9 I ) with hemispherical radiation in a room with little reflection Table H3 2: Unit type reference Table H3 3: Sound level of TopVent MK 124

127 TopVent MK Technical Data Air inlet temperature 1) LPHW Unit type C 10 C Q t S H max m W p W kw C m l / h kpa 15 C Q t S H max m W p W kw C m l / h kpa 20 C Q t S H max m W p W kw C m l / h kpa 90 / 70 MK-6 / C I MK-9 / C I MK-9 / D I 80 / 60 MK-6 / C I MK-9 / C I MK-9 / D I / 50 MK-6 / C I MK-9 / C I MK-9 / D I / 40 MK-6 / C I MK-9 / C I MK-9 / D I H 82 / 71 MK-6 / C I MK-9 / C I MK-9 / D I ) The air inlet temperatures (10/ 15 / 20 C) correspond to room air temperature. The given heat outputs relate to a fresh air rate of 20 % (at -10 C); i.e. the mixed temperatures at the coil inlet are 6 / 10 / 14 C. Operating conditions not allowed because the maximum supply air temperature of 60 C is exceeded. Legend: Q = Heat output t S = Supply air temperature H max = Maximum mounting height m W = Water flow rate p W = Water pressure drop Table H3 4: Heat outputs of TopVent MK 125

128 TopVent MK Technical Data MK-6 Cooling medium temp. t ai rh Unit type C % MK-6 / C I 50 MK-6 / C I 70 MK-6 / C I 6 / 12 C Q tot Q sen t S m C m W p W 8 / 14 C Q tot Q sen t S m C m W p W 10 / 16 C Q tot Q sen t S m C m W p W kw kw C kg / h l / h kpa kw kw C kg / h l / h kpa kw kw C kg / h l / h kpa MK-6 / C I 50 MK-6 / C I 70 MK-6 / C I MK-6 / C I 50 MK-6 / C I 70 MK-6 / C I ) The air inlet temperatures (24/ 26 / 28 C) correspond to room air temperature. The given cooling capacities relate to a fresh air rate of 20 % (at + 32 C); i.e. the mixed temperatures at the coil inlet are 25.6 / 27.2 / 28.8 C. Legend: t ai = Air inlet temperature rh = Air inlet humidity Q tot = Total cooling capacity Q sen = Sensible cooling capacity p W = Water pressure drop Table H3 5: Cooling capacity of TopVent MK-6 t S m C m W = Supply air temperature = Amount of condensate = Water flow rate 126

129 TopVent MK Technical Data MK-9 Cooling medium temp. t ai rh Unit type C % MK-9 / C I 50 MK-9 / C I 70 MK-9 / C I 6 / 12 C Q tot Q sen t S m C m W p W 8 / 14 C Q tot Q sen t S m C m W p W 10 / 16 C Q tot Q sen t S m C m W p W kw kw C kg / h l / h kpa kw kw C kg / h l / h kpa kw kw C kg / h l / h kpa MK-9 / C I 50 MK-9 / C I 70 MK-9 / C I MK-9 / C I 50 MK-9 / C I 70 MK-9 / C I MK-9 / D I 50 MK-9 / D I 70 MK-9 / D I H MK-9 / D I 50 MK-9 / D I 70 MK-9 / D I MK-9 / D I 50 MK-9 / D I 70 MK-9 / D I ) The air inlet temperatures (24 / 26 / 28 C) correspond to room air temperature. The given cooling capacities relate to a fresh air rate of 20 % (at + 32 C); i.e. the mixed temperatures at the coil inlet are 25.6 / 27.2 / 28.8 C. Legend: t ai = Air inlet temperature Q sen = Sensible cooling capacity rh = Air inlet humidity Q tot = Total cooling capacity t S m C = Supply air temperature = Amount of condensate m W = Water flow rate p W = Water pressure drop Table H3 6: Cooling capacity of TopVent MK-9 127

130 TopVent MK Technical Data Return Flow Rp ¾" (female) Condensate drain Inspection port Unit type A mm B mm C mm D mm E mm F mm G mm H mm J " K mm L mm O x P mm R mm T mm Weight kg Water content of coil l MK-6 / C Rp 1¼ (female) x MK-9 / C Rp 1½ (female) x MK-9 / D Rp 2 (female) x Table H3 7: Dimensions and weights of TopVent MK 128

131 TopVent MK Technical Data Maximum operating pressure 800 kpa Maximum heating medium temperature 120 C Maximum supply air temperature 60 C Maximum ambient temperature 40 C Maximum amount of condensate MK-6 Maximum amount of condensate MK-9 Minimum air flow rate MK-6 Minimum air flow rate MK-9 40 kg 90 kg 3100 m³ / h 5000 m³ / h Table H3 8: Application limits of TopVent MK W X Y H Unit type Fan speed Wall distance W min. m max. m Unit distance X min. m (centre to centre) max. m Mounting height Y min. m I MK-6 / C MK-9 / C I MK-9 / D I Table H3 9: Minimum and maximum distances 129

132 TopVent MK Technical data MK-6 / C MK-6 / C speed speed I Pressure drop increase in Pa Example: An additional pressure drop of 33 Pa at 4100 m³/h results in a new air flow rate of 3700 m³/h Air flow rate in m³ / h Diagram H3 1: Air flow rate for TopVent MK-6 with additional pressure drop MK-9 / C MK-9 / D MK-9 / C MK-9 / D speed speed speed I speed I Pressure drop increase in Pa Air flow rate in m³ / h Diagram H3 2: Air flow rate for TopVent MK-9 with additional pressure drop 130

133 TopVent MK Options 4 Options A wide range of accessories allows customisation of TopVent MK units for each individual project. For a detailed description of all optional components please refer to part K 'Options' of this handbook. Paint finish Suspension set Isolation switch Actuator for Air-Injector Actuator for mixed air box Acoustic cowl Insulation Condensate pump In the Hoval standard colours red / orange (for free) or in any desired colour (extra charge) For fastening the unit to the ceiling External on / off mains switch For adjustment of the Air-Injectors when using a non-hoval control system (for Hoval control equipment see section 5 'Control systems') For adjustment of the fresh air and recirculation dampers when using a non-hoval control system (for Hoval control equipment see section 5 'Control systems') For lowering the noise level in the room (reduced noise radiation from the Air-Injector) Prevents condensation forming on the outer surfaces of the mixed air box, the filter box and the Air-Injector For condensate drainage through waste water pipes under the ceiling or onto the roof Table H4 1: Options available with TopVent MK H 131

134 TopVent MK Control Systems 5 Control systems For TopVent MK units, specially developed and optimised components for room temperature, air distribution and fresh air rate control are available from Hoval. For a detailed description of these components please refer to part L 'Control systems' of this handbook. 5.1 Integrated system DigiNet (detailed description on request) Ideally, TopVent MK units are controlled by DigiNet. This is an integrated system that has been specially developed for Hoval indoor climate systems. It controls room temperature as well as air distribution and constantly optimises the fresh air rate (i.e. just as much fresh air is taken in as necessary to maintain the room temperature without additional heating or cooling). Table H5 1: Integrated control system for TopVent MK 5.2 Air distribution control Automatic control with the VarioTronic The VarioTronic is an electronic controller for the Air-Injector. It adjusts air distribution for changing operating conditions (fan speed, temperature difference between supply air and room air) and works independently of room temperature control. Manual control by means of potentiometer and actuator Where operating conditions change rarely or comfort requirements are not so high, air distribution may be controlled manually by means of a potentiometer. Fixed adjustment Where the basic conditions remain unchanged (constant supply air temperature, constant air flow rate), air distribution can be manually fixed at commissioning. Table H5 2: Air distribution control systems for TopVent MK 132

135 TopVent MK System Design 6 System design Example Usually, the primary function of TopVent DKV units is cooling; for this reason the design process is described for this function. The design for heating can be made in a similar way to the example in part G 'TopVent MH'. Collect basic data Space dimensions (floor plan) Mounting height (= distance from floor to underside of the TopVent unit) Required cooling capacity Desired room conditions Cooling medium temperature (flow / return) Comfort requirements (acoustic) Fresh air temperature Minimum fresh air flow rate (The fresh air rate can be adjusted as desired between 0 % and 100 %; for an efficient use of energy the design calculation is to be based on a minimum value.) Space dimensions...40 m x 62 m Mounting height m Required cooling capacity kw Desired room conditions...26 C / 50 % Cooling medium temperature... 8 / 14 C Comfort requirements...standard Fresh air temperature...32 C Minimum fresh air flow rate m³ / h Comfort requirements (acoustic) According to acoustic requirements define the fan speed: Low sound level low fan speed (speed I) Normal sound level high fan speed (speed ) In this project the acoustic requirements are 'standard', hence use the high fan speed (speed ) for design calculations. H Mounting height With the minimum mounting height (table E3-8) check which units can be used. According to table H3-9 the minimum mounting heights are: MK m MK m Consequently, all sizes can be used in this project with a mounting height of 6.5 m. Minimum and maximum number of units For determining the minimum number of units three criteria must be fulfilled: a) Minimum number relating to floor area Table H3-1 indicates the maximum floor area that can be reached with TopVent MK units. With these values and the given floor area the minimum number of units can be determined for each unit size and coil type. b) Minimum number relating to space dimensions (length x width) Depending on space dimensions, a certain minimum number of units are required in the length and in the width. This can be calculated from the maximum distances between units and to the wall (see table H3-9). Calculate the minimum numbers according to a), b) and c) for each unit type and enter them in a table. Then take the highest value as minimum number of units d). Calculate the maximum possible number according to e) and enter the values in the table. 133

136 TopVent MK System Design c) Minimum number relating to cooling capacity The minimum number for each unit size and coil type can be calculated from the required total cooling capacity (table H3-5 and H3-6). Please note that only the sensible cooling capacity Q sen is available for cooling of the space while the total capacity Q tot must be used for sizing the chiller. Type a) b) c) d) e) MK-6 / C MK-9 / C MK-9 / D d) Effective minimum number of units The highest value of the foregoing calculations a), b) and c) is the effective minimum number of units that should be installed. e) Maximum number of units The minimum number determined under d) normally corresponds to the solution selected in practice as it incurs the lowest costs. Yet if comfort requirements are particularly high more units may be provided. The maximum number of units is theoretically determined from the total floor area divided by the minimum floor area reached per unit X 2 (X = minimum distance between units, see table H3-9). Definite number of units According to space dimensions, comfort requirements and costs, select the optimum solution from the remaining alternatives. Due to the space dimensions, comfort requirements and the investment made available the solution with 6 TopVent MK is selected. Fresh air rate Calculate the minimum fresh air rate from the air flow rate of the selected units (see table H3-1) and the required minimum fresh air flow rate. Total air flow rate: 6 x 7100 m³ / h = m³ / h Minimum fresh air flow rate: 8500 m³ / h Minimum fresh air rate: 20 % Automatic control Group units working under equal operating conditions (room temperature, cooling load, operating times) into control zones. Check maximum switching power of the controller. Check if, in view of operating conditions, automatic control of the air distributor with the VarioTronic is worthwhile. The low-cost solution is 2 TempTronic controllers: Switching power = 3 x 1.65 kw < 6.5 kw 3 x 1.65 kw < 6.5 kw The maximum floor area reached depends on the one hand on local conditions and on the other hand on the quality of air distribution. Due to the complexity of air flow mechanisms in large rooms the design quantities can only partly be mathematically described. The quality of the air distributor affects the supplied energy made available in the occupied area as a function of the air flow rate, the temperature difference between supply air and room air and the mounting height. Tests on the test rig and the experience of numerous applications show that with the Air-Injector this conversion of energy is effected with considerably higher efficiency than with other air distributors usually employed in recirculation units. This higher quality leads to lower running costs as well as to a larger floor area reached and thus fewer units are needed. To facilitate the design process concerning the floor area reached we have decided to dispense with complicated formulas and diagrams. However, it is important to keep to the limiting values and to make sure that the primary and secondary air flow can spread unhindered. If the given limits are exceeded in your application please seek Hoval advice. 134

137 TopVent MK Transport and Installation 7 Transport and installation Transport and installation to be carried out by experts only! A lifting appliance is required for transportation and installation of the units! Do not tilt or lay the unit on its side! 7.1 Installation For fastening to the ceiling, the unit is equipped with four M10 captive nuts with hexagon head screws and washers as standard. With these and the height adjustable suspension set (option) the unit is easily fixed to the ceiling. The captive nuts are only designed for the unit's own weight. Do not put on any additional loads! The captive nuts cannot sustain a bending moment; therefore do not use eyebolts! Installation by means of steel flat, slotted steel flat, angle or steel wire is also possible, but the following has to be considered: Non-vertical suspensions are permissible up to a maximum angle of 45. The unit must be installed with its top face horizontal (level)! For connection to the fresh air duct it is advisable to install a flexible connector. 7.2 Hydraulic installation Hydraulic installation to be carried out by experts only! Combine units working under equal operating conditions (room temperature, heat gain, operating time, etc.) into one control zone. Low or medium pressure hot water up to 120 C can be used as a heating medium. To save energy, the distributor can be pre-calibrated; it should, however, be ensured that the heat requirement of each heater battery can always be met. Connect the individual heating / cooling coils as shown in figure G7 2. Depending on local conditions, it should also be considered whether compensations for flow and return pipework are needed to balance the longitudinal expansion and / or flexible connections for the units. The heat exchanger cannot take up any extra load, e.g. through the flow or return pipe. Adequately size the slope and cross section of the condensate drain to prevent a condensate backwash. Install a 200 mm trap. The individual units within a control zone must be hydraulically balanced to ensure even temperatures. H max. 45 max. 45 Air vent Balancing valve Drain cocks Isolating valves Flow Return Condensate drain (with trap) 2-port valve Fig. H7 1: Suspension of TopVent MK Fig. H7 2: Heating / cooling coil connection 135

138 TopVent MK Transport and Installation 7.3 Electrical installation The electrical connections to the unit must be carried out by an electrical expert. Relevant regulations must be observed. The unit is delivered ready for use. Check that the local operating voltage, frequency and fusing are in accordance with the information on the nameplate. If any discrepancies occur the unit must not be connected! Check cable diameters when using long wiring runs. Electrical installation to be carried out according to the wiring diagram for the control equipment. Connection of the TopVent units to be carried out according to the wiring diagram. Connect thermal relays built into the motor; otherwise the motor is not protected against overheating. Do not forget to install a main switch for the whole system (control, units). Several TopVent units can be connected in parallel. Thermal relays and isolation switches must be wired in series! The condensate separator works only with the fan running. Therefore, switch off the cooling pump together with the fan. Isolation switch (optional) Low fan speed (Y connection) Filter pressure switch Actuator for mixed air box (optional) Switch position L Thermal relay Fan (wiring by the installer) High fan speed ( connection) (wiring by the installer) Fig. H7 3: Wiring diagram for TopVent MK 136

139 TopVent MK Specification Texts 8 Specification texts TopVent MK Supply air unit for ventilating, heating and cooling high spaces Casing made of corrosion-resistant Aluzinc sheet steel. For fastening to the ceiling, the unit is equipped with four M10 captive nuts with hexagon head screws and washers as standard. Heat exchanger of copper tubes with aluminium fins. Headers are made of steel. A condensate separator with drain connection is installed. Fan unit consisting of a 2-speed three-phase motor of the external-rotor type with rigid sickle-shaped aluminium blade impeller, maintenance-free and quiet at high efficiency. Motor protection with built-in thermal relays. Protection rating IP54. Filter box with two bag filters class G4, incl. differential pressure switch for supervision of filter cleaning intervals. Mixed air box made of Aluzinc sheet steel with fresh air / recirculation dampers. Terminal box built into the casing sidewall for connection of mains supply and accessories. Vortex air distributor with concentric outlet nozzle, twelve adjustable guide vanes and integrated sound attenuation cowl. Technical data Fan speed I Nominal air flow rate m³ / h Floor area reached m² Mounting height m Nominal cooling capacity kw with chilled water C air inlet temperature C and air inlet humidity % Nominal heating capacity kw with LPHW C and air inlet temperature C Power consumption kw Current consumption A Voltage 400 V / 50 Hz MK-6 / C MK-9 / C MK-9 / D Special paint finish AL In RAL colour No. Suspension set AHS For fastening the units to the ceiling, consisting of 4 pairs of Aluzinc steel U sections, height adjustable up to 1300 mm. Paint finish as for the unit. Isolation switch RS In the terminal box of the TopVent unit. Actuator for Air-Injector VT-A Complete with cable, for adjustment of the Air-Injector when using a non-hoval control system. Actuator for mixed air box MLK-A With cable, for adjustment of the fresh air and recirculation dampers when using a non-hoval control system Acoustic cowl AHD Consisting of a sound attenuation cowl with bigger volume and a faceplate with sound-insulation lining, insertion attenuation 4 db(a). Insulation ID of the Air-Injector of the filter box of the mixed air box Condensate pump KP Consisting of a centrifugal pump, collecting tray and flexible hose, delivery output max. 80 l / h at 3 m delivery height. H Standard paint finish SL In the Hoval colours red (RAL 3000) and orange (RAL 2008). 137

140 TopVent MK Specification Texts Automatic air distribution control with the VarioTronic Electronic controller with well-proven control algorithm for changing operating conditions. VarioTronic VT-W, control module built as wall unit, in a plastic casing with transparent lid VarioTronic VT-S, control module for installation in a control panel (without casing, transformer, contactor and fuses) Cylinder lock ZS for VarioTronic wall unit Actuator VT-AK with cable, plug, supply air sensor and room air sensor Actuator VT-AS with cable and plug Separate room air sensor TS1 Manual air distribution control with the potentiometer Manual control by means of a potentiometer and actuator with a range of 0 to 50 for adjustment of the air discharge angle between vertical and horizontal. Potentiometer wall unit PMS-W Potentiometer for installation in a control panel PMS-S Actuator VT-AS with cable and plug Transformer TA for maximum 7 actuators 138

141 1 Intended use Function and construction Technical data Options Control systems System design Transport and installation Specification texts 151 TopVent HV I Recirculation unit heater for rooms with up to 6 m height

142 TopVent HV Intended Use 1 Intended use TopVent HV are recirculation unit heaters for use in rooms with up to 6 m height. Correct usage also entails adherence to the manufacturer's conditions for installation, initial start-up, operation and maintenance (operating instructions) as well as consideration of possible malfunctions and of hazards. 1.1 User group TopVent units are only to be installed, operated and serviced by authorised and trained specialists who are familiar with and have been instructed on the hazards. The operating instructions are for English-speaking works engineers and technicians as well as specialists in building, heating and ventilation technology. 1.2 Modes of operation TopVent HV units have the following operating modes: Recirculation heating at low fan speed Recirculation heating at high fan speed Standby Off The application limits given in the 'Technical Data' section must be observed. Any utilisation beyond this is considered inappropriate. The manufacturer is not liable for any damages resulting therefrom. In standard design the units are not suitable for use in explosive atmospheres, in high humidity areas or in rooms with a high dust load. 1.3 Hazards Despite all of the preventive measures that have been taken, there are certain hazards, which may not be obvious, e.g.: Danger when working on the electrical system Items (e.g. tools) can drop down when work is being done on the TopVent unit Malfunctions due to defective parts Danger from hot water when working on the heating system 140

143 TopVent HV Function and Construction 2 Function and construction The TopVent HV unit is used for recirculation heating; it has been specially developed for application in rooms up to 6 m height. The unit is installed under the ceiling, takes in room air, heats it by means of the heater battery and injects it back into the room via the outlet louvre. The unit is available in three sizes, each with a two-speed fan as standard so that altogether six different heat outputs can be selected. The TopVent HV consists of the fan and the heater battery, installed in a casing of galvanised sheet steel. An outlet louvre with individually adjustable guide vanes is fitted at the base of the casing. Casing: consisting of galvanised sheet steel Fan: two-speed axial fan Heat exchanger: LPHW heater battery consisting of copper tubes with aluminium fins Terminal box Outlet louvre: guide vanes for manual adjustment of air distribution I Fig. I2 1: Construction of TopVent HV 141

144 TopVent HV Technical Data 3 Technical data Unit type Fan speed RPM (nominal) min -1 Nominal air flow rate m³ / h Floor area reached 1) max. m² Power consumption (at 400 V / 50 Hz) kw Current consumption (at 400 V / 50 Hz) A HV-2 I ) Mounting height H max = 5 m up to 30 K temperature difference supply air - room air HV-3 I HV-5 I Table I3 1: Technical data of TopVent HV Unit type reference Unit type TopVent HV Unit size 2, 3 or 5 HV 2 Unit type Fan speed Sound pressure level (5 m distance) 1) db(a) Total sound power level db(a) Octave sound power level 63 Hz db 125 Hz db 250 Hz db 500 Hz db 1000 Hz db 2000 Hz db 4000 Hz db 8000 Hz db HV-2 I HV-3 I HV-5 I ) with hemispherical radiation in a room with little reflection Table I3 2: Unit type reference Table I3 3: Sound levels of TopVent HV 142

145 TopVent HV Technical Data Air inlet temperature LPHW Unit type C 10 C Q t S H max m W p W kw C m l / h kpa 15 C Q t S H max m W p W kw C m l / h kpa 20 C Q t S H max m W p W kw C m l / h kpa 90 / 70 HV-2 I HV-3 I HV-5 I / 60 HV-2 I HV-3 I HV-5 I / 50 HV-2 I HV-3 I HV-5 I / 40 HV-2 I HV-3 I HV-5 I I 82 / 71 HV-2 I HV-3 I HV-5 I Legend: Q = Heat output t S = Supply air temperature H max = Maximum mounting height m W = Water flow rate p W = Water pressure drop Table I3 4: Heat outputs of TopVent HV 143

146 TopVent HV Technical Data D 300 Rp 1" M8 Rp 1" C B A Unit type A B C D Weight Water content of heater battery mm mm mm mm kg l HV HV HV Table I3 5: Dimensions and weights of TopVent HV Maximum operating pressure 800 kpa Maximum heating medium temperature 120 C Maximum supply air temperature 60 C Maximum ambient temperature 40 C Table I3 6: Application limits of TopVent HV 144

147 TopVent HV Technical Data D Z W X Y Unit type Fan speed Unit height R m Wall distance W min. m max. m Unit distance X min. m (centre to centre) max. m Mounting height Y min. m Ceiling distance Z min. m HV-2 I HV-3 I HV-5 I Table I3 7: Minimum and maximum distances I 145

148 TopVent HV Control Systems 4 Options No optional components are available for TopVent HV. 5 Control systems For TopVent HV units, specially developed and optimised components for room temperature control are available from Hoval. For a detailed description of these components please refer to part L 'Control systems' of this handbook. TempTronic EasyTronic This is a programmable, electronic temperature controller allowing fully automatic operation. Its control algorithm with fuzzy logic ensures smallest room temperature deviations from setpoints and minimises energy consumption. This is a basic temperature controller without clock. The desired room temperature is manually adjusted and the fan speed selected with a switch. Table I5 1: Room temperature control systems for TopVent HV 146

149 TopVent HV System Design 6 System design Example Collect basic data Space dimensions (floor plan) Mounting height (= distance from floor to underside of the TopVent unit) Required heat output Desired room temperature Heating medium temperature (flow / return) Comfort requirements (acoustic) Space dimensions...10 m x 22 m Mounting height m Required heat output...38 kw Desired room temperature...20 C Heating medium temperature / 40 C Comfort requirements...high Comfort requirements (acoustic) According to acoustic requirements define the fan speed: Low sound level low fan speed (speed I) Normal sound level high fan speed (speed ) In this project the acoustic requirements are 'high', hence use the low fan speed (speed I) for design calculations. Mounting height With the minimum mounting height (table I3-7) check which units can be used. Check maximum mounting height according to heating medium temperature and inlet air temperature (= room temperature) (table I3-4). Eliminate units that cannot be used. According to table I3-7 the minimum mounting heights are: HV-2, HV-3, H m Consequently, all sizes can be used in this project with a mounting height of 4.5 m. According to table I3-4 and the given conditions (heating medium temperature 60 / 40 C, inlet air temperature 20 C) the following unit types cannot be employed due to the maximum mounting height: HV-5... H max = 4.2 m I Minimum and maximum number of units For determining the minimum number of units three criteria must be fulfilled: a) Minimum number relating to floor area Table I3-1 indicates the maximum floor area that can be reached with TopVent HV units. With these values and the given floor area the minimum number of units can be determined for each unit size. b) Minimum number relating to space dimensions (length x width) Depending on space dimensions, a certain minimum number of units are required in the length and in the width. This can be calculated from the maximum distances between units and to the wall (see table I3-7). c) Minimum number relating to heat output The minimum number for each unit size can be calculated from the required total heat output (table I3-4). Calculate the minimum numbers according to a), b) and c) for each unit type and enter them in a table. Then take the highest value as minimum number of units d). Calculate the maximum possible number according to e) and enter the values in the table. 147

150 TopVent HV System Design d) Effective minimum number of units The highest value of the foregoing calculations a), b) and c) is the effective minimum number of units that should be installed. e) Maximum number of units The minimum number determined under d) normally corresponds to the solution selected in practice as it incurs the lowest costs. Yet if comfort requirements are particularly high more units may be provided. The maximum number of units is theoretically determined from the total floor area divided by the minimum floor area reached per unit X 2 (X = minimum distance between units, see table I3-7). Type a) b) c) d) e) HV HV HV-5 no solution Definite number of units According to space dimensions, comfort requirements and costs, select the optimum solution from the remaining alternatives. Due to the space dimensions, comfort requirements and the investment made available the solution with 8 TopVent HV-2 is selected. Automatic control Group units working under equal operating conditions (room temperature, heat demand, operating times) into control zones. Check maximum switching power of the controller. The low-cost solution is 1 TempTronic controller for all 8 units: Switching power = 8 x 0.08 kw < 6.5 kw 148

151 TopVent HV Transport and Installation 7 Transport and installation Transport and installation to be carried out by experts only! A lifting appliance is required for transportation and installation of the units! Do not tilt or lay the unit on its side! 7.1 Installation For fastening to the ceiling, the unit is equipped with four M8 captive nuts with hexagon head screws and washers as standard. With these the unit is easily fixed to the ceiling by means of steel flat, angle or steel wire. The captive nuts are only designed for the unit's own weight. Do not put on any additional loads! The captive nuts cannot sustain a bending moment; therefore do not use eyebolts! 7.2 Hydraulic installation Hydraulic installation to be carried out by experts only! Combine units working under equal operating conditions (room temperature, heat gain, operating time, etc.) into one control zone. Low or medium pressure hot water up to 120 C can be used as a heating medium. To save energy, the distributor can be pre-calibrated; it should, however, be ensured that the heat requirement of each heater battery can always be met. Connect the individual heating coils as shown in figure I7 2. Depending on local conditions, it should also be considered whether compensations for flow and return pipework are needed to balance the longitudinal expansion and / or flexible connections for the units. The heat exchanger cannot take up any extra load, e.g. through the flow or return pipe. The individual units within a control zone must be hydraulically balanced to ensure even temperatures. Non-vertical suspensions are permissible up to a maximum angle of 45. The unit must be installed with its top face horizontal (level)! I max. 45 max. 45 Air vent Balancing valve Drain cocks Isolating valves Flow Return Fig. I7 1: Suspension of TopVent HV Fig. I7 2: Heating coil connection 149

152 TopVent HV Transport and Installation 7.3 Electrical installation The electrical connections to the unit must be carried out by an electrical expert. Relevant regulations must be observed. The unit is delivered ready for use. Check that the local operating voltage, frequency and fusing are in accordance with the information on the nameplate. If any discrepancies occur the unit must not be connected! Check cable diameters when using long wiring runs. Electrical installation to be carried out according to the wiring diagram for the control equipment. Connection of the TopVent units to be carried out according to the wiring diagram. Connect thermal relays built into the motor; otherwise the motor is not protected against overheating. Do not forget to install a main switch for the whole system (control, units). Several TopVent units can be connected in parallel. Thermal relays must be wired in series! Fan Low fan speed (Y connection) U1 V1 W1 W2 U2 V2 TK TK Thermal relay (wiring by the installer) High fan speed ( connection) U1 V1 W1 W2 U2 V2 TK TK (wiring by the installer) Fig. I7 3: Wiring diagram for TopVent HV 150

153 TopVent HV Specification Texts 8 Specification texts TopVent HV Recirculation unit heater for rooms with up to 6 m height Casing made of galvanised sheet steel. For fastening to the ceiling, the unit is equipped with four M8 threaded bolts with nuts and washers as standard. Heat exchanger of copper tubes with aluminium fins. Headers are made of steel. Fan unit consisting of a 2-speed three-phase motor of the external-rotor type with rigid aluminium die-cast blade impeller, maintenance-free and quiet at high efficiency. Motor protection with built-in thermal relays. Protection rating IP44. Terminal box built into the casing sidewall for connection of mains supply. Outlet louvre with individually adjustable guide vanes. Technical data Fan speed I Nominal air flow rate m³ / h Floor area reached m² Mounting height m Nominal heating capacity kw with LPHW C and air inlet temperature C Power consumption kw Current consumption A Voltage 400 V / 50 Hz HV-2 HV-3 HV-5 Room temperature control with the TempTronic Electronic controller with 2-speed 2-point control, fuzzy logic, clock with automatic summer / winter changeover and holiday programme. TempTronic SH, controller for heating operation, built as wall unit in a plastic casing with transparent lid, room air sensor included TempTronic SH-S, controller for heating operation, built for installation in a control panel (without casing, transformer, contactors and fuses), room air sensor included Three additional room air sensors for averaging TS1M Cylinder lock ZS for TempTronic wall unit Room temperature control with the EasyTronic Basic controller with 2-point control and manual fan speed switching. EasyTronic ET, controller for heating operation, built as wall unit in a plastic casing with transparent lid, room thermostat included I 151

154 152

155 1 Intended use Function and construction Technical data Options Control systems System design Transport and installation Specification texts 163 TopVent curtain J Air curtain

156 TopVent curtain Intended Use 1 Intended use The TopVent curtain is a recirculation unit heater with outlet nozzle; it is used as an air curtain for doors of up to 6 m height. Correct usage also entails adherence to the manufacturer's conditions for installation, initial start-up, operation and maintenance (operating instructions) as well as consideration of possible malfunctions and of hazards. 1.1 User group TopVent units are only to be installed, operated and serviced by authorised and trained specialists who are familiar with and have been instructed on the hazards. The operating instructions are for English-speaking works engineers and technicians as well as specialists in building, heating and ventilation technology. 1.2 Modes of operation TopVent curtain have the following operating modes: Recirculation heating at low fan speed Recirculation heating at high fan speed Standby Off The application limits given in the 'Technical Data' section must be observed. Any utilisation beyond this is considered inappropriate. The manufacturer is not liable for any damages resulting therefrom. The units are not suitable for use in explosive atmospheres, in high humidity areas or in rooms with a high dust load. 1.3 Hazards Despite all of the preventive measures that have been taken, there are certain hazards, which may not be obvious, e.g.: Danger when working on the electrical system Items (e.g. tools) can drop down when work is being done on the TopVent unit Malfunctions due to defective parts Danger from hot water when working on the heating system 154

157 TopVent curtain Function and Construction 2 Function and construction The TopVent curtain is a recirculation unit heater with outlet nozzle; it is used as an air curtain for doors of up to 6 m height. Several TopVent curtain units are fitted above the door. The units take in room air, heat it by means of the heater battery and blow it downwards through the outlet nozzles. The air curtain so generated minimises external influences on the indoor climate. It prevents cold air from entering and increases the useful floor area in the space. The unit is available in three sizes, each with a two-speed fan as standard so that altogether six different heat outputs can be selected. The TopVent curtain consists of the heating section (with fan and heater battery) and the outlet nozzle. Heating section Outlet nozzle Fig. J2 1: TopVent curtain unit components Casing: consisting of galvanised sheet steel Fan: two-speed axial fan Heat exchanger: LPHW heater battery consisting of copper tubes with aluminium fins Terminal box Outlet nozzle J Fig. J2 2: Construction of TopVent curtain 155

158 TopVent curtain Technical Data 3 Technical data Unit type Fan speed RPM (nominal) min -1 Nominal air flow rate m³ / h Power consumption (at 400 V / 50 Hz) kw Current consumption (at 400 V / 50 Hz) A CUR-2 I CUR-3 I CUR-5 I Table J3 1: Technical data of TopVent curtain Unit type reference Unit type TopVent curtain Unit size 2, 3 or 5 CUR 2 Unit type Fan speed Sound pressure level (5 m distance) 1) db(a) Total sound power level db(a) Octave sound power level 63 Hz db 125 Hz db 250 Hz db 500 Hz db 1000 Hz db 2000 Hz db 4000 Hz db 8000 Hz db CUR-2 I CUR-3 I CUR-5 I ) with hemispherical radiation in a room with little reflection Table J3 2: Unit type reference Table J3 3: Sound level of TopVent curtain 156

159 TopVent curtain Technical Data Air inlet temperature LPHW Unit type C 10 C Q t S m W p W kw C l / h kpa 15 C Q t S m W p W kw C l / h kpa 20 C Q t S m W p W kw C l / h kpa 90 / 70 CUR-2 I CUR-3 I CUR-5 I / 60 CUR-2 I CUR-3 I CUR-5 I / 50 CUR-2 I CUR-3 I CUR-5 I / 40 CUR-2 I CUR-3 I CUR-5 I / 71 CUR-2 I CUR-3 I CUR-5 I J Legend: Q = Heat output t S m W = Supply air temperature = Water flow rate p W = Water pressure drop Table J3 4: Heat outputs of TopVent curtain 157

160 TopVent curtain Technical Data A B C 300 M8 D Rp 1" Rp 1" E x F Unit type A B C D E x F Weight Water content of heater battery mm mm mm mm mm x mm kg l CUR x CUR x CUR x Table J3 5: Dimensions and weights of TopVent curtain Maximum operating pressure 800 kpa Maximum heating medium temperature 120 C Maximum supply air temperature 60 C Maximum ambient temperature 40 C Table J3 6: Application limits of TopVent curtain 158

161 TopVent curtain Control Systems 4 Options No optional components are available for TopVent curtain. 5 Control systems For TopVent curtain units, a specially developed controller is available from Hoval. For a detailed description please refer to part L 'Control systems' of this handbook. CurTronic This is a programmable, electronic temperature controller allowing fully automatic operation. It switches the unit on or off depending on the door contact switch and heat demand. Table J5 1: Controller for TopVent curtain J 159

162 TopVent curtain System Design 6 System design When designing indoor climate systems for large spaces special attention must be paid to external influences through open doors, since unprotected doors are the cause of considerable energy loss and discomfort. To avoid such problems, air curtains may be installed (cf. diagrams J6 1 and J6 2). In general, the function of air curtains is supported by a slight positive pressure in the room. This can be achieved by installing additional fresh air and / or mixed air units. 6.1 Calculation program For designing air curtain installations a calculation program can be supplied. It determines the required number of TopVent curtain units per door based on the following criteria: The required air flow rate is calculated from the door size, the difference in density between room air and outdoor air and the wind velocity. The spacing between TopVent curtain units must not exceed ¾ of the unit width. The point of intersection of the primary air flows must be in the upper half of the door. 6.2 Quick selection Table J6 1 may be used for quick selection. The given values apply for winter conditions ( 16 C outside temperature, 20 C room temperature, normal position). Losses [MWh/ year] Door height [m] Door width [m] Diagram J6 1: Energy loss through unprotected doors Savings [%] Door height [m] Diagram J6 2: Normal energy savings with air curtains H x/2 x H/ m Door size Width Height 2 m 2 m 3 m 2 m 3 m 3 m 4 m 3 m 4 m 4 m 5 m 4 m 5 m 5 m 6 m 5 m Number of units CUR-2 CUR-3 CUR B Table J6 1: Required number of TopVent curtain unit for different door sizes (reference values) H = Door height B = Door width x = Unit spacing Fig. J6 1: Plant layout 160

163 TopVent curtain Transport and Installation 7 Transport and installation Transport and installation to be carried out by experts only! A lifting appliance is required for transportation and installation of the units! Do not tilt or lay the unit on its side! 7.1 Installation First check if the heater battery connections and outlet nozzle are in the required position. If not, loosen the bolted connection between the nozzle and the heating section, turn the nozzle as required and secure in place. For fastening to the ceiling, the unit is equipped with four M8 captive nuts with hexagon head screws and washers as standard. With these and the use of steel flat or angle the unit is easily fixed above the door according to the plant layout (i.e. with the calculated spacings). The captive nuts are only designed for the unit's own weight. Do not put on any additional loads! 7.2 Hydraulic installation Hydraulic installation to be carried out by experts only! Combine units working under equal operating conditions (room temperature, heat gain, operating time, etc.) into one control zone (recommendation: pipework system according to Tichelmann). Low or medium pressure hot water up to 120 C can be used as a heating medium. To save energy, the distributor can be pre-calibrated; it should, however, be ensured that the heat requirement of each heater battery can always be met. Connect the individual heating coils as shown in figure J7 2. Depending on local conditions, it should also be considered whether compensations for flow and return pipework are needed to balance the longitudinal expansion and / or flexible connections for the units. The heat exchanger cannot take up any extra load, e.g. through the flow or return pipe. The individual units within a control zone must be hydraulically balanced to ensure even temperatures. The captive nuts cannot sustain a bending moment; therefore do not use eyebolts! The unit must be installed with its top face horizontal (level)! Air vent Balancing valve Drain cocks Isolating valves Flow Return J Fig. J7 1: Turn outlet nozzle to the required position Fig. J7 2: Heating coil connection 161

164 TopVent curtain Transport and Installation 7.3 Electrical installation The electrical connections to the unit must be carried out by an electrical expert. Relevant regulations must be observed. The unit is delivered ready for use. Check that the local operating voltage, frequency and fusing are in accordance with the information on the nameplate. If any discrepancies occur the unit must not be connected! Check cable diameters when using long wiring runs. Electrical installation to be carried out according to the wiring diagram for the control equipment. Connection of the TopVent units to be carried out according to the wiring diagram. Connect thermal relays built into the motor; otherwise the motor is not protected against overheating. Do not forget to install a main switch for the whole system (control, units). Several TopVent units can be connected in parallel. Thermal relays must be wired in series! Fan Low fan speed (Y connection) U1 V1 W1 W2 U2 V2 TK TK Thermal relay (wiring by the installer) High fan speed ( connection) U1 V1 W1 W2 U2 V2 TK TK (wiring by the installer) Fig. J7 3: Wiring diagram for TopVent curtain 162

165 TopVent curtain Specification Texts 8 Specification texts TopVent curtain Air curtain Casing made of galvanised sheet steel. For fastening and suspension, the unit is equipped with four M8 threaded bolts with nuts and washers as standard. Heat exchanger of copper tubes with aluminium fins. Headers are made of steel. Fan unit consisting of a 2-speed three-phase motor of the external-rotor type with rigid aluminium die-cast blade impeller, maintenance-free and quiet at high efficiency. Motor protection with built-in thermal relays. Protection rating IP44. Terminal box built into the casing sidewall for connection of mains supply. Outlet nozzle made of galvanised sheet steel. Technical data Fan speed I Nominal air flow rate m³ / h Nominal heating capacity kw with LPHW C and air inlet temperature C Power consumption kw Current consumption A Voltage 400 V / 50 Hz CUR-2 CUR-3 CUR-5 Room temperature control with the CurTronic Electronic controller with 2-speed 2-point control, fuzzy logic, clock with automatic summer / winter changeover and holiday programme, additionally switched by means of a door contact switch with overrun CurTronic CT, controller for heating operation, built as wall unit in a plastic casing with transparent lid, room air sensor included CurTronic CT-S, controller for heating operation, built for installation in a control panel (without casing, transformer, contactors and fuses), room air sensor included Three additional room air sensors for averaging TS1M Cylinder lock ZS for CurTronic wall unit J 163

166 164

167 1 Availability Paint finish Suspension set Isolation switch Actuator Filter box Flat filter box Acoustic cowl Recirculation silencer Air outlet box Insulation Condensate pump Hydraulic assembly Explosion-proof design 173 Options K

168 TopVent Options 1 Availability The following optional components are available for TopVent units: Paint-finish Suspension set Isolation switch Actuator for Air-Injector Actuator for mixed air box Filter box Flat filter box Acoustic cowl Recirculation silencer Air outlet box Insulation Condensate pump Hydraulic assembly Explosion-proof design TopVent DHV 1) TopVent DKV TopVent NHV 1) TopVent commercial CAU TopVent commercial CUM TopVent MH TopVent MK TopVent HV TopVent curtain 1) Only the unit sizes 6 and 9 are available in explosion-proof design. Legend: = Not available = Available as option = Standard feature. Table K1 1: Availability of options 166

169 TopVent Options 2 Paint finish 4 Isolation switch If desired all TopVent units (standard Aluzinc) can be painted. There are two possibilities: 2.1 Standard paint finish The individual unit components can be painted in Hoval standard colours for free: Air-Injector, air outlet box orange (RAL 2008) Heating section, heating cooling section red (RAL 3000) Suspension set red (RAL 3000) Filter box, Flat filter box red (RAL 3000) Mixed air box red (RAL 3000) Recirculation silencer red (RAL 3000) Roof hood not painted 2.2 Special paint finish To match the room colour, all unit components can be painted in any desired colour (extra charge; indicate RAL number on the order). 3 Suspension set The suspension set secures the TopVent units to the ceiling. It comprises 4 pairs of Aluzinc steel U sections with holes for height adjustment up to 1300 mm (bolts and nuts included). An external on / off switch for the fan can be installed in the terminal box of the TopVent units. Only the fan is switched off with the isolation switch. Control components (such as the VarioTronic) can still be live! 5 Actuator 5.1 Actuator for Air-Injector For adjusting the Air-Injector by means of a non-hoval control system an actuator (type VT-A) can be supplied. This adapts the Air-Injector vanes in a range from 0 (= vertical air supply) to 50 (= horizontal air supply). The mechanical stops are to be adjusted correspondingly. To ensure the correct vane position even after switch-on, the actuator always performs the following starting cycle (duration about 3 min): Actual position 0 50 desired position 5.2 Actuator for mixed air box For adjusting the fresh air and recirculation dampers by means of a non-hoval control system an actuator (type MLK-A) can be supplied. This adjusts the dampers in a range from 0 (= 0 % fresh air) to 90 (= 100 % fresh air). To ensure the correct damper position even after switch-on, the actuator always performs the following starting cycle (duration about 3 min): Actual position 0 90 Desired position Fig. K3 1: Suspension set K Fig. K5 1: Actuator 167

170 TopVent Options 6 Filter box Filter box For filtering recirculated air a filter box can be fitted (or retrofitted) on TopVent DHV and TopVent DKV units. This contains two bag filters class G4 (according to DIN EN 779). The modular construction made of Aluzinc sheet steel with two sliding doors allows easy filter exchange. Please note that in front of the sliding doors there must be sufficient space for exchanging the filters Due to the additional pressure drop, the performance data of the respective TopVent units decrease: Air flow rate (and mounting height) by approx. 13 % Heating and cooling capacities by approx. 8 % Type VT-A MLK-A Nominal voltage AC 24 V, 50 Hz AC 24 V, 50 Hz Control signal Y DC V DC V Operating range DC V DC V Torque 8 Nm 8 Nm Running time 150 s 150 s 6.2 Filter pressure switch For automatic filter supervision a filter pressure switch can be installed. This indicates when the filters must be cleaned or exchanged. Factory setting 180 Pa Switching contacts for 24 V DC, 20 ma Table K5 1: Dimensions and technical data of the actuators for Air-Injector (VT-A) and for mixed air box (MLK-A) AC 24 V! Connect via safety isolating transformer Y DC V U DC V Y U VT-A MLK-A Fig. K5 2: Connection diagram of the actuators for Air-Injector (VT-A) and for mixed air box (MLK-A) Type FK-6 FK-9 / 10 A mm Q mm Total filter area m² Filter dimensions mm 740 x 370 x x 470 x 300 Number of filters 2 2 Weight kg Table K6 1: Dimensions and weights of filter box 168

171 TopVent Options 7 Flat filter box 9 Recirculation silencer 7.1 Flat filter box For filtering recirculated air the TopVent commercial UM can be equipped with a flat filter box (retrofitting possible). This contains four V-cell filters class G4. Due to the additional pressure drop, the performance data of the TopVent units decrease: Air flow rate (and mounting height) by approx. 9 % Heating and cooling capacities by approx. 8 % 7.2 Filter pressure switch For automatic filter supervision a filter pressure switch can be installed. This indicates when the filters must be cleaned or exchanged. Factory setting 180 Pa Switching contacts for 24 V DC, 20 ma The use of a recirculation silencer for lowering the noise level is recommended mainly where TopVent units are installed below smooth, hard ceilings (e.g. concrete or steel sheet ceilings). The recirculation silencer is fitted on top of the unit to reduce noise reflection from the ceiling. The insertion attenuation compared with the total sound power level of the respective TopVent unit in standard design is 3 db(a). As normally, use the 4 suspension points provided in the heating or heating / cooling section for fastening the unit (e.g. using the optional suspension set). Do not suspend the unit by the silencer! The silencer cannot take up the weight of the TopVent unit! Type FFK-9 Total filter area m² 8.8 Filter dimensions mm 495 x 495 x 47 Number of filters 4 Weight kg 11 A Table K7 1: Dimensions and weights of flat filter box H 8 Acoustic cowl To reduce the sound power level, an Air-Injector with enhanced sound insulation can be used. This differs from the standard design as follows: The sound attenuation cowl is replaced by a cowl with bigger volume. An additional faceplate with sound-insulation lining is installed. The outside dimensions of the Air-Injector remain the same. The insertion attenuation compared with the total sound power level of the respective TopVent unit in standard design is 4 db(a). Type USD-6 USD-9 / 10 A mm H mm Weight kg Table K9 1: Dimensions and weights of recirculation silencer K 169

172 TopVent Options 10 Air outlet box 11 Insulation For using TopVent units in low height rooms an air outlet box can be installed in place of the Air-Injector, reducing the minimum mounting height by 1 m compared with the standard design. The air outlet box has horizontal grilles on all four sides. These can be manually adjusted (without tools) for adapting the air discharge angle to local conditions. The air outlet box replaces the Air-Injector. Consequently, the total unit height is reduced; the weight remains approximately the same. The insulation prevents condensation from humid room air forming on the cold outer walls of TopVent units, which may occur in cooling operation or when fresh air passes through the unit. In addition, the sound level is lowered a little. Insulation is available for the following components: Air-Injector Mixed air box Filter box The heating / cooling section in the TopVent units is insulated as standard. Polyethylene insulating material Thermal conductivity 0.04 W / mk Closed pore Insensitive to pressure Non-abrasive Flame resistant (B1) Temperature range C Table K11 1: Technical data of insulation Fig. K10 1: TopVent DHV with air outlet box Heating section or heating / cooling section The outside dimensions of TopVent units are the same with or without insulation. The increase in pressure drop due to the reduced cross-sectional area is insignificant. Insulation is necessary if the outside surface temperature is lower than the dew point temperature of room air. When determining the dew point temperature of room air, take into consideration that the humidity at the height of the TopVent unit is normally higher than the humidity in the occupied area. The surface temperature can be approximated as follows: t Sf = t R 0.75 (t R t S ) t Sfi = t R 0.25 (t R t S ) t Sf... Surface temperature t Sfi... Surface temperature with insulation t R... Room temperature (at the height of the TopVent unit) t S... Supply air temperature Type AK-6 AK-9 / 10 A mm H mm Weight kg Table K10 1: Dimensions and weights of air outlet box 170

173 TopVent Options 12 Condensate pump 13 Hydraulic assembly For TopVent cooling units a condensate drain must be installed. For applications where connection to the waste water system is too costly or impossible due to building structures a condensate pump can be supplied. This pump is fitted at the side of the unit, directly below the condensate connection. It pumps the condensate through a plastic tube up to a delivery height of 3 m and thus allows for condensate drainage through waste water pipes under the ceiling, onto the roof. For TopVent commercial units prefabricated hydraulic assemblies are available (diverting system). There are two different designs, distinguished only by the mixing valve: Hydraulic assembly for fresh air HG8D-AU (fast solenoid actuator) Hydraulic assembly for recirculation HG8D-UM (actuator with 75 second actuation time) The assembly is not insulated. The proper function can only be ensured if installed horizontally. Hydraulic balancing Pre-set the balancing valves according to the required pressure drop in the distribution circuit. The values can be easily read from diagram K13 1. The curves 1.0 to 4.0 represent the turns of the valve spindle; they are shown on the rotary knob: 0.0 Valve closed 4.0 Valve fully opened The indicated pressure drops include the coil and the hydraulic assembly. Consider pressure drops in the distribution system only up to the screw joints (Pos. 7). Fig. K12 1: Condensate pump fitted below the condensate connection The weight of the hydraulic assembly cannot be taken up by the coil. Type KP-6 / 9 Delivery output max. 80 l / h at 3 m delivery height Tank capacity max. 0.5 l Dimensions 185 x 85 x 100 mm (L x W x H) Weight 1.6 kg Power supply 230 VAC, 50 / 60 Hz, 65 VA Wiring factory-wired Table K12 1: Technical data for the condensate pump Pressure drop in kpa K Pump 1 x 230 V Alarm contact Fig. K12 2: Wiring diagram for condensate pump Water flow rate in l / h Diagram K13 1: STAD setting for the hydraulic assemblies HG8D-AU and HG8D-UM 171

174 TopVent Options Mixing valve Balancing valve STAD DN 50 Ball valve Automatic air vent Drain cock Flow / return pipe adapter with screw joint to coil Screw joint to distribution circuit 2" ~120 ~750 Flow Fresh air Recirculation Return Fig. K13 1: Dimensions of hydraulic assembly (in mm) Type HG8D-AU HG8D-UM Mixing valve MXG HV VXP Actuator ASE2 SSC619 Power supply AC 24 V / 50 Hz AC 24 V / 50 Hz Control signal DC V DC V Actuation time < 1 s 75 s Maximum operating pressure 10 bar Heating / cooling medium temperature C Ambient temperature C Maximum air humidity 95 % rh (29 g / m 3 ) Table K13 2: Application limits of hydraulic assembly Table K13 1: Technical data for hydraulic assembly 172

175 TopVent Options 14 Explosion-proof design TopVent units with explosion-proof components are suitable for use in spaces where explosive atmospheres may occur. Please note the following: The components pump, valve and control panel must be installed outside of the explosive sphere (see figure K14 1). The units are suitable for application in zone 1 and zone 2, however not in zone 0 (according to DIN EN , VDE 0165 part 101: ). Zone 0 Areas where explosive atmospheres exist continuously or for a long time. Zone 1 Areas where it is to be expected that explosive atmospheres occasionally occur. Zone 2 Areas where it is to be expected that explosive atmospheres occur only rarely and for a short time. TopVent units EEx are suitable for use in temperature class T3: Max. permissible surface temperature 200 C Ignition temperature of gases and vapours > 200 C The maximum permissible ambient temperature is 40 C. Prior to commissioning, the installation must be inspected and approved by local authorities. The following TopVent units are available with explosionproof components: DHV-6 / A EEx DHV-6 / B EEx DHV-6 / C EEx DHV-9 / A EEx DHV-9 / B EEx DHV-9 / C EEx NHV-6 / A EEx NHV-6 / B EEx NHV-6 / C EEx NHV-9 / A EEx NHV-9 / B EEx NHV-9 / C EEx Table K14 1: TopVent unit available with explosion-proof components The unit construction differs from the standard design as follows: A one-speed radial fan in explosion-proof design is installed. Electrical components are replaced by explosion-proof designs. Vulnerable electric circuits are replaced by intrinsically safe circuits. Materials where static electricity can build-up are adapted or replaced (spark discharge) Technical data The technical data differ from the standard unit design as follows: Air flow rate (and mounting height) Size 6 approx. 8 % lower than standard speed Size 9 same as standard speed Heat output Size 6 approx. 6 % lower than standard speed Size 9 same as standard speed Motor data (see table K14 3) Sound level (see table K14 4) Explosion-proof components (see table K14 5) Dimensions and weights (see table K14 6) EN EN EN VDMA part 1 VDE 0170 / 0171, part 1-6 BGR 132 Table K14 2: Standards taken into consideration K Explosive sphere Fig. K14 1: Pump, valve and control panel must be installed outside of the explosive sphere. 173

176 TopVent Options 14.2 Options TopVent units with explosion-proof components are available with the following options: Paint finish Suspension set Filter box in explosion-proof design (incl. filter pressure switch) Other options may be applied, yet require adaptation for use in explosive atmospheres. For details please ask Hoval application advice. Unit type RPM (nominal) Power consumption (at 400 V / 50 Hz) kw Size Current consumption (at 400 V / 50 Hz) A 1.35 Table K14 3: Motor data of TopVent units with explosion-proof components Size 6 Size 9 Size System design The following must be taken into consideration for applications in explosive atmospheres: The pump, valve and control panel must be installed outside of the explosive sphere. Provide a main switch for the whole system. Fan motor protection is by means of a PTC resistor (DIN / 2-M130) in connection with a trigger device (by the installer). All required temperature sensors located in the explosive sphere must be wired to the control panel with an intrinsically safe circuit (isolating transformer). The isolating transformer must be installed in the control panel, outside of the explosive sphere. The filter pressure switch (option) is to be wired to the control panel with an intrinsically safe circuit (isolation amplifier) by the installer. Intrinsically safe circuits must be run separately from other electrical circuits and specially marked (label connection terminals, use light blue cables). Fan 3 x 400 V PCT resistor Fan 3 x 400 V Y connection Fig. K14 2: Wiring diagram for TopVent units with explosion-proof components Unit type Sound pressure level (5 m distance) 1) db(a) Total sound power level db(a) Octave sound power level 63 Hz db 125 Hz db 250 Hz db 500 Hz db 1000 Hz db 2000 Hz db 4000 Hz db 8000 Hz db 1) with hemispherical radiation in a room with little reflection Size PTC resistor Size Table K14 4: Sound powers of TopVent units with explosion-proof components Designation Type Ignition protection Approving authority No. of CE test certificate 3-phase motor size 6 MK DK.14.Y EEx e T3 PTB 01 ATEX 3349X / 12 3-phase motor size 9 MK DK.20.Y EEx e T3 PTB 03 ATEX 3118X / 04 Terminal box GHG EEx e T6 PTB 99 ATEX 1044 Table K14 5: Explosion-proof components 174

177 TopVent Options Marking of Explosion-Proof Devices 25 E 4 x M10 T N F H G Example: EEx d C T3 Mark for electric devices with a conformity certificate of an EU inspection body (EC directive 76 / 117 / EEC) B C J Return Flow R E Ex Built to European Standards EN to EN Explosion-proof electric device Unit type A mm B mm C mm T mm E mm F mm G mm H mm J " N mm R mm Weight DHV EEx kg NHV EEx kg Size Rp 1¼ (female) A Size Rp 1½ (female) d C T3 Type of ignition protection o = Oil enclosure p = Pressure enclosure q = Sand enclosure d = Explosion-containing enclosure e = Enhanced safety m = Potting i = Intrinsically safe (category a or b) Group classification I = Firedamp protection = Explosion protection Exact group specification A, B, C (only for protection types 'd' and 'i') Temperature classification Maximum permissible Ignition temperature surface temperature of gases and vapours T1 = 450 C > 450 C T2 = 300 C > 300 C T3 = 200 C > 200 C T4 = 135 C > 135 C T5 = 100 C > 100 C T6 = 85 C > 85 C Table K14 6: Dimensions and weights of TopVent units with explosionproof components K 175

178 176

179 1 Availability TempTronic EasyTronic CurTronic Air distribution control Fresh air rate control Basic control 201 Control Systems L

180 TopVent Control Systems 1 Availability The following control components are available for TopVent units: Integrated system Fresh air rate control Air distribution control Room temperature control TempTronic (for heating) TempTronic (for heating and cooling) EasyTronic Basic control CurTronic Automatic control with the VarioTronic Manual control with potentiometer and actuator Manual control with potentiometer and actuator DigiNet TopVent DHV TopVent DKV TopVent NHV TopVent commercial CAU TopVent commercial CUM TopVent MH TopVent MK TopVent HV TopVent curtain Table L1 1: Availability of control components 178

181 TopVent Control Systems 2 TempTronic The TempTronic is an electronic controller for TopVent recirculation and supply air units. Construction The TempTronic consists of: the control module (with micro-controller for room temperature control, clock, setting potentiometers and terminal strips) and the room air sensor; this must be installed at a position typical of the occupied area and connected to the control module. It is available in different designs: Type Use Design SH Heating Wall unit SHK Heating and cooling Wall unit SH-S Heating For control panel SHK-S Heating and cooling For control panel Table L2 1: TempTronic types In wall unit design, the TempTronic control module is installed in a plastic casing with transparent lid. It can be protected from unauthorised access with a cylinder lock (option). In the design for control panel, the control module is installed in the front cover or door of a control panel. The transformer required for power supply and the contactors needed for speed switching are part of the control panel. 2-point control with fuzzy logic The TempTronic controls the TopVent units in relation to heat demand. To save energy, a 2-point controller (on / off) is used. Due to the integrated feedback, however, switching the different speeds on and off depends on other criteria than with conventional 2-point controllers, reducing deviations. Two set values Two desired values for room temperature can be set. Switching between the two values is by means of the clock. Room set value ( C) While this value is effective the units are switched on and off always at the required speed. Reduction / increase ( t) The adjusted value lowers the room set value in heating mode and raises it in cooling mode. When in operating mode 'Auto.' and this value is effective, the TopVent units run at high speed only, keeping heating / cooling times to a minimum and thus saving energy. Frost protection The control algorithm also contains an automatic frost protection switch: As soon as the room temperature falls below 5 C the units switch on (running at high speed in the operating modes 'Auto.' and 'Off' and at low speed in operating mode 'Auto. I'). On reaching a room temperature of 7 C the units switch off again. With the selector switch for heating / cooling operation in position 'Cooling' the frost protection switch is not effective! Faults If a fan motor is switched off by the thermal relay both speed indication lamps show red. All units in the group are switched off. To restart after clearing the cause of the fault, turn the selector switch to and then to the desired operating mode. A power failure is not indicated, however, when power is again available the TempTronic automatically switches back to the previous operating mode. L Fig. L2 1: TempTronic wall unit 179

182 TopVent Control Systems Clock Shortest switching time 1 min Storing capacity 42 Accuracy ±1 s per day Power reserve 4 days Lamp indications I (Y) ( ) Speed I on green Speed on green Motor fault red red Switched off externally blinking green blinking green Frost protection switch or green blinking red Sensor fault blinking red alternately Isolation switch off or filter dirty blinking red blinking red Selector switch for heating / cooling This switch allows switching between heating and cooling operation (only type SHK or SHK-S). Selector switch for operating modes Auto.: Fully automatic operation depending on heat / cool demand and selecting the desired room temperatures by the clock. Auto. I: Like 'Auto.' but with the fans running at low speed only. : The controller and the TopVent units are off. (or: release after a fault) I (Y): The TopVent units run at low speed, without control. ( ): The TopVent units run at high speed, without control. Integration constant (ki) Setting of the feedback amplification. For normal plants, a setting of about 50 is recommended. In applications where the heat output of the units significantly excedes fabric heat losses ki should be set to a value < 50 the heat output of the units roughly corresponds to fabric heat losses ki should be set to a value > 50. Reduction / increase of the room set value ( t) Setting of the temperature change in degrees (e.g. during the night or weekend). The adjusted value lowers the room set value in heating mode and raises it in cooling mode. Room set value ( C) Setting of the desired room temperature 180

183 TopVent Control Systems Technical data TempTronic wall unit SH / SHK Supply voltage 3 x 400 VAC ±10 % Frequency Hz Mains fuse max. 16 A Switching power max. 6.5 kw Own consumption 5 VA Protection rating IP 65 Dimensions (W x H x D) 215 x 185 x 110 mm Ambient temperature C Technical data TempTronic for control panel SH-S / SHK-S Control voltage 24 VAC Frequency Hz Mains fuse max. 0.5 A Switching power max. 48 VA Own consumption 2 VA Dimensions (W x H x D) 206 x 118 x 30 mm Opening in control panel 182 x 110 mm Ambient temperature C Setting ranges Room set value ( C) C Reduction / increase ( t) K Integration constant (ki) % Temperature sensor TS1 Dimensions (W x H x D) 50 x 65 x 35 mm Range C Protection rating IP54 Installation Power supply and connection of the TopVent units must be carried out according to the wiring diagram and all applicable regulations. Several TopVent units can be controlled with one Temp- Tronic. Only units working under equal operating conditions (switching times, temperature, etc.) may be linked in a group. Thermal relays and indication of the isolation switches must be wired in series! If the TempTronic is installed in a control panel the motor contactors for stardelta speed switching (rating depending on total power), a 24 V transformer and the corresponding terminal strip must be installed in the control panel. Plug X1 Earth 23 Collective alarm Speed I VDC - B 27 Ext. indication speed I Speed 29 Ext. indication speed VDC - A 32 External switching (off) 33 Room air sensor TS Isolation switch 36-(27) Thermal relay 37-(27) Plug X2 (only for SHK-S) Contact for heating pump Contact for cooling pump Table L2 2: Terminal designation on TempTronic for control panel TempTronic SH / SHK control module 2 x 1.5 mm 2 2 x 1.5 mm 2 7 x 1.5 mm 2 (ev. 2.5 mm 2 ) max. 6.5 kw Room air sensor TS1 parallel series Further TopVent units 3 x 400 VAC Hz max. 16 A L TopVent unit Fig. L2 2: Wiring diagram for TempTronic wall unit 181

184 TopVent Control Systems External switching In position 'Auto.' or 'Auto. I' the plant can be switched off externally (e.g. from a central station). In this case both lamps start blinking green. External speed indication The current fan speed can be indicated externally, e.g. in a central station (volt-free). Wall unit 0 = Fan 'Off' I = Fan 'Auto' 3 x 1.5 mm² Speed on Control panel 0 = Fan 'Off' I = Fan 'Auto' 24 VB Speed on Indication 'Isolation switch off' If the TopVent units are equipped with isolation switches and at least one of these is off, both lamps start blinking red. Collective alarm In case of a problem a collective alarm can be given externally via a volt-free contact (motor fault, isolation switch off, power failure, sensor break, sensor short-circuit, frost protection mode). 3 x 1.5 mm² (without PE) max. 48 V / 1 A TopVent unit 2 x 1.5 mm² Alarm 2 x 1.5 mm² (without PE) max. 48 V / 1 A max. 48 V / 1 A 24 VB TopVent unit Alarm max. 48 V / 1 A Switching of the VarioTronic If a VarioTronic is used for air distribution control, this can be switched between stage 1 and 2 according to the fan speed with the TempTronic. If you want to combine external speed indication and switching of the VarioTronic, wiring is as follows: VarioTronic VT-W 2 x 1.5 mm² Suppressor element (RC element / varistor) VarioTronic VT-S Suppressor element (RC element / varistor) Speed on VT-W max. 48 V / 1 A 3 x 1.5 mm² (without PE) Speed on max. 48 V / 1 A VT-S Switching of the pump The heating or cooling pump for the unit group can be switched with the TempTronic. It is also possible to switch a valve or other motors (volt-free). Mean value of room temperature Instead of one room air sensor, four sensors can be installed for averaging. Suppressor element (RC element / varistor) H = Heating K = Cooling 3 x 1.5 mm² (without PE) max. 48 V / 1 A max. 48 V / 1 A Suppressor element (RC element / varistor) H = Heating K = Cooling Table L2-3: External switching possibilities for TempTronic 182

185 TopVent Control Systems External clock This function offers the possibility to effect switching between the two set values externally. Factory setting: The built-in clock and thus the week programme are active. Jumper I Jumper Jumper position Factory setting Switching of the temperature set values by a superior system or by means of a manual switch: The built-in clock is disabled. To select this function, wiring of the terminals A and B and jumper settings I and are as follows: Jumper I T = Day (room set value) N = Night (reduction / increase) Jumper Wiring External clock Jumper position External clock Commissioning Commissioning may only be carried out by an authorised and trained expert. Before commissioning, the installation of the TempTronic and the TopVent units must be fully completed. The user manual for the units must be to hand. We recommend the following procedure: Set fan speeds I and with the selector switch and check whether fans rotate in the correct direction. Rectify any wiring errors. Check motor protection switch (thermal relay): Loosen the thermal relay cable (TK) of at least one unit motor protection is set off. Check room air sensor: Is it installed in a typical location? Is the sensor possibly affected by machines or other heat sources? Set the unit to 'Auto.' and check the function by adjusting the set value. Set the desired room temperature ( C). Set the desired reduction / increase ( t). Adjust the integration constant (ki). Programme the clock. Connection in parallel of several TempTronic controllers: In an application with several control zones, a pilot TempTronic (with active clock) controls the week programme for other TempTronic controllers. Thus, the week programme needs to be entered only once whilst temperature set values can be adjusted individually for each zone. 1 st TempTronic 2 nd TempTronic (pilot) (and others) Jumper I Jumper I Jumper Jumper Wiring Connection in parallel Jumper position Connection in parallel Pilot TempTronic Jumper position Connection in parallel 2 nd TempTronic and others Switch off display: If desired, the clock display can be switched off, as follows: Jumper I Jumper 1-2 entfernen Jumper position Display off Jumper I Fig. L2 3: Remove lid of the TempTronic controller for setting the jumpers I and Jumper L 183

186 TopVent Control Systems 3 EasyTronic The EasyTronic is a switching device with simple temperature control for TopVent DHV, NHV and HV units. Construction The EasyTronic consists of: the control box (with selector switch for operating modes) installed in a plastic casing with transparent lid for wallmounting, the room thermostat; this must be installed in the occupied area and connected to the control box. Temperature control The EasyTronic switches the TopVent units depending on heat demand. The operating mode is manually selected at the control box: 0 The TopVent units are off. 1 On / off operation of the TopVent units with speed 1 (= low speed) 2 On / off operation of the TopVent units with speed 2 (= high speed) The desired temperature is selected at the room thermostat with a rotary knob. As soon as the room temperature falls below the set value the TopVent units switch on at the selected speed. On reaching the set value the units switch off again. The EasyTronic does not produce a signal for switching a heating pump or heat generator. Frost protection The EasyTronic can be switched to frost protection manually: Turn the selector switch to operating mode '1' or '2' and adjust the reduced temperature (e.g. 5 C) at the room thermostat. Faults When a fan motor is switched off by the thermal relay the EasyTronic switches off. To restart after the motor has cooled down, turn the selector switch to '0' and then to the desired operating mode again (or disconnect power supply for a short time). Technical data control box Supply voltage 3 x 400 VAC ±10 % Frequency Hz Mains fuse 10 A Switching power max. 4 kw Protection rating IP 54 Dimension (W x H x D) 166 x 230 x 129 mm Ambient temperature C Technical data room thermostat Dimension (W x H x D) 74 x 74 x 23 mm Range C Protection rating IP 30 Installation Power supply and connection of the TopVent units must be carried out according to the wiring diagram and all applicable regulations. Several TopVent units can be controlled with one Easy- Tronic. Only units working under equal operating conditions (switching times, temperature, etc.) should be linked in a group. Thermal relays must be wired in series! Fig. L3 1: EasyTronic control box Fig. L3 2: EasyTronic room thermostat 184

187 TopVent Control Systems Fig. L3 3: Dimensions of the EasyTronic control box EasyTronic control box Mains 3~400V 50 / 60Hz / N Motor 3~ with built-in thermal relays OFF / ON Fig. L3 4: Wiring diagram for EasyTronic L 185

188 TopVent Control Systems 4 CurTronic The CurTronic is an electronic controller for TopVent curtain units. Construction The CurTronic consists of: the control module (with micro-controller for room temperature control, clock, setting potentiometers and terminal strips); this must be connected to the door contact switch by the installer. and the room air sensor; this must be installed near the door and connected to the control module. It is available in two designs: Type CT CT-S Design CurTronic wall unit CurTronic for control panel Table L4 1: Types of CurTronic In wall unit design, the CurTronic control module is installed in a plastic casing with transparent lid. It can be protected from unauthorised access with a cylinder lock (option). In the design for control panel, the control module is installed in the front cover or door of a control panel. Hence the transformer required for power supply and the contactors needed for speed switching are part of the control panel. 2-point control with fuzzy logic The CurTronic controls the TopVent curtain units in relation to heat demand. To save energy, a 2-point controller (on / off) is used. Due to the integrated feedback, however, switching the different speeds on and off depends on other criteria than with conventional 2-point controllers, reducing deviations. Two set values Two desired values for room temperature can be set. Switching between the two values is by means of the clock. Room set value ( C) While this value is effective the units are switched on and off always at the required speed. Reduction ( t) The adjusted value lowers the room set value. When in operating mode 'Auto.' and this value applies, the TopVent units run at high speed only, keeping heating times to a minimum and thus saving energy. Door operation The CurTronic switches the TopVent curtain units depending on the door contact switch: As soon as the door opens the door contact switch closes and the units switch on (at high speed). When the door is shut the units switch on after the adjustable fan overrun. Frost protection The control algorithm also contains an automatic frost protection switch: As soon as the room temperature falls below 5 C the units switch on (at high speed). On reaching a room temperature of 7 C the units switch off again. Faults If a fan motor is switched off by the thermal relay both speed indication lamps show red. All units in the group are switched off. To restart after clearing the cause of the fault, turn the selector switch to and then to the desired operating mode. A power failure is not indicated, however, when power is again available the CurTronic automatically switches back to the previous operating mode. Fig. L4 1: CurTronic wall unit 186

189 TopVent Control Systems Clock Shortest switching time 1 min Storing capacity 42 Accuracy ±1 s per day Power reserve 4 days Lamp indications I (Y) ( ) Speed I on green Speed on green Motor fault red red Door open or fan overrun blinking green green Frost protection switch blinking red Sensor fault blinking red alternately Isolation switch off blinking red blinking red C 20 min CurTronic Auto. I Auto. Selector switch for operating modes Auto. I: Automatic operation depending on the door contact switch: Door OPEN: The units run at high speed. Door SHUT: The units switch off after the adjusted fan overrun (0-10 min). Auto.: Automatic operation depending on the door contact switch and, additionally, depending on the heat demand and the desired room temperatures switched by the clock. : The controller and the connected units are off. (or: release after a fault) I (Y): The TopVent units run at low speed, without control. ( ): The TopVent units run at high speed, without control. Fan overrun (min) Setting of the fan overrun after door closure in minutes Reduction of the room set value ( t) Setting of the room temperature reduction (e.g. during the night or weekend) in degrees L Room set value ( C) Setting of the desired room temperature 187

190 TopVent Control Systems Technical data CurTronic wall unit CT Supply voltage 3 x 400 VAC ±10 % Frequency Hz Mains fuse max. 16 A Switching power max. 6.5 kw Own consumption 5 VA Protection rating IP 65 Dimensions (W x H x D) 215 x 185 x 110 mm Ambient temperature C Installation Power supply and connection of the TopVent units must be carried out according to the wiring diagram and all applicable regulations. Several TopVent units can be controlled with one CurTronic. Only units working under equal operating conditions (door area) may be linked in a group. Thermal relays must be wired in series! Technical data CurTronic for control panel CT-S Supply voltage 24 VAC Frequency Hz Mains fuse max. 0.5 A Switching power max. 48 VA Own consumption 2 VA Dimensions (W x H x D) 206 x 118 x 30 mm Opening in control panel 182 x 110 mm Ambient temperature C Setting ranges Room set value ( C) C Reduction ( t) K Fan overrun (min) min Temperature senor TS1 Dimensions (W x H x D) 50 x 65 x 35 mm Range C Protection rating IP54 If the CurTronic is installed in a control panel the motor contactors for stardelta speed switching (rating depending on total power), a 24 V transformer and the corresponding terminal strip must be installed in the control panel. Plug X1 Earth 23 Collective alarm Speed I VDC - B 27 Ext. indication speed I Speed 29 Ext. indication speed VDC - A 32 Door contact switch 33 Room air sensor TS Isolation switch 36-(27) Thermal relay 37-(27) Table L4 2: Terminal designation on CurTronic for control panel CurTronic CT control module A B U1 V1 W1 W2 U2 V2 PE L1 L2 L3 Room air sensor TS1 3 x 1.5 mm 2 (24 V AC) 2 x 1.5 mm 2 2 x 1.5 mm 2 7 x 1.5 mm 2 (ev. 2.5 mm 2 ) max. 6.5 kw parallel series Further TopVent units 3 x 400 VAC Hz max. 16 A Door contact: I = Door shut 0 = Door open U1 V1 W1 W2 U2 V2 TK TK TopVent curtain Fig. L4 2: Wiring diagram for CurTronic wall unit 188

191 TopVent Control Systems External speed indication The current fan speed can be indicated externally, e.g. in a central station (volt-free). Wall unit Speed on Control panel Speed on 3 x 1.5 mm² (without PE) max. 48 V / 1 A max. 48 V / 1 A Indication 'Isolation switch off' If the TopVent units are equipped with isolation switches and at least one of these is off, both lamps start blinking red. (Remove bridge if isolation switches are connected.) 2 x 1.5 mm² 24 VB Collective alarm In case of a problem a collective alarm can be given externally via a volt-free contact (motor fault, isolation switch off, power failure, sensor break, sensor short-circuit, frost protection mode). Alarm 2 x 1.5 mm² (without PE) max. 48 V / 1 A max. 48 V / 1 A Alarm Table L4-3: External switching possibilities for CurTronic L 189

192 TopVent Control Systems External clock This function offers the possibility to effect switching between the two set values externally. Factory setting: The built-in clock and thus the week programme are active. Jumper I Jumper Jumper position Factory setting Switching of the temperature set values by a superior system or by means of a manual switch: The built-in clock is disabled. To select this function, wiring of the terminals A and B and jumper settings I and are as follows: Jumper I T = Day (room set value) N = Night (reduction / increase) Jumper Wiring External clock Jumper position External clock Connection in parallel of several CurTronic controllers: In an application with several control zones, a pilot CurTronic (with active clock) controls the week programme for other CurTronic controllers. Thus, the week programme needs to be entered only once whilst temperature set values can be adjusted individually in each CurTronic. 1 st CurTronic 2 nd CurTronic (pilot) (and others) Commissioning Commissioning may only be carried out by an authorised and trained expert. Before commissioning, installation of the CurTronic and the TopVent units must be fully completed. The user manual for the units must be to hand. We recommend the following procedure: Set fan speeds I and with the selector switch and check whether fans rotate in the correct direction. Rectify any wiring errors. Check motor protection switch (thermal relay): Loosen the thermal relay cable (TK) of at least one unit motor protection is set off. Check door contact switch: Set CurTronic to 'Auto.' or 'Auto. I' and check the function by opening and shutting the door. Check room air sensor: Is it installed near the door? Is the sensor possibly affected by machines or other heat sources? Set the unit to 'Auto.' and check the function by adjusting the set value. Set the desired room temperature ( C). Set the desired reduction ( t). Adjust the fan overrun (min). Programme the clock. Jumper I Jumper I Jumper Jumper Wiring Connection in parallel Jumper position Connection in parallel Pilot CurTronic Jumper position Connection in parallel 2 nd CurTronic and others Switch off display: If desired, the clock display can be switched off, as follows: Jumper I Remove jumper 1-2 Jumper position Display off Jumper I Fig. L4 3: Remove lid of the CurTronic controller for setting the jumpers I and Jumper 190

193 TopVent Control Systems 5 Air distribution control The Air-Injector introduces supply air at various temperatures and flow rates into the occupied area of high spaces, without causing draughts. This is achieved by means of a controllable vane arrangement allowing continuous adjustment of the air discharge angle between vertical and horizontal. 5.1 Air distribution with the Air-Injector Supply air enters the vane arrangement from above. The air discharge direction changes with the vane angle as follows: With the vanes in radial position (vane angle = 0 ) the air passes through the air distributor without being influenced, that is without twist. It is injected into the space vertically downwards. If the vanes are at an angle the air jet opens up. The air spreads out and the throw is thus reduced. With the vanes in the extreme position (vane angle = 50 ) this effect is so strong that the supply air flow passes along the underside of the air outlet (Coanda effect) and thus is supplied into the space horizontally. Fig. L5 1: Vane angle The vane angle depends on: the mounting height the air flow rate (With a lower air flow rate also the air velocity and thus the throw decrease. To compensate for this, the twist must be reduced.) the temperature difference between supply air and room air ( heating / cooling, see figure L5-2) Adjustment of the Air-Injector can be done automatically (with the electronic controller VarioTronic) or manually (by means of a potentiometer and actuator). In certain cases air distribution can be permanently set during commissioning. Isothermal. In isothermal operation the room and supply air temperatures are the same. The necessary twist depends only on the mounting height and on the air flow rate (and thus on the fan speed). Heating. Supply air is warmer than room air and thus lighter; it rises in the space. Therefore, the greater the positive temperature difference between supply air and room air, the more the twist must be reduced to ensure that the supply air reaches the occupied area. Cooling. Supply air is colder than room air and due to its higher density sinks to the occupied area. Because this can easily cause draughts, the air must be blown into the space more horizontally in cooling operation. L Fig. L5 2: Varying operating conditions of the Air-Injector 191

194 TopVent Control Systems 5.2 Automatic air distribution control with the VarioTronic The VarioTronic is an electronic controller for the Air-Injector. It adjusts the air discharge angle to changing operating conditions and works independently of room temperature control. Construction The VarioTronic consists of the following components: VarioTronic control module Two designs are available: VarioTronic wall unit (VT-W): The control module incl. the transformer is installed in a plastic casing with transparent lid. It can be protected from unauthorised access with a cylinder lock (option). VarioTronic for control panel (VT-S): The control module is installed in a compact block with relay plug for installation on a relay base. Fig. L5 3: VarioTronic wall unit Drive unit Actuator for Air-Injector The configuration of the drive unit differs depending on use (see table L5-3). The actuator adjusts the Air-Injector vanes in a range from 0 (= vertical air supply) to 50 (= horizontal air supply). To ensure the correct vane position even after switch-on, the actuator always performs the following starting cycle (duration about 3 min): Actual position 0 50 Desired position Supply air sensor The supply air sensor is installed in the Air-Injector. Its position between the vanes ensures that the correct supply air temperature is sensed in all operating modes Room air sensor The room air sensor is installed in a terminal box in the Air-Injector. For most applications this is an adequate position to ensure the correct function and its response time to room temperature variations is sufficient. With big temperature differences between working level and mounting height a separate room air sensor may be an advantage (option). This can be installed at a suitable position in the occupied area. Type Nominal voltage Control signal Y Operating range Torque Running time VT-A AC 24 V, 50 Hz DC V DC V 8 Nm 150 s Fig. L5 1: Construction of the VarioTronic Table L5 2: Dimensions and technical data for the actuator (VT-A) 192

195 TopVent Control Systems Type VT-A VT-AK VT-AS VT-AD Components Actuator with cable Actuator with cable, plug, supply air and room air sensor (type KTY) Actuator with cable and plug Actuator with cable, plug and supply air sensor (type Ni1000) Use For non-hoval control For VarioTronic control in independent units For VarioTronic control in pilot units for connection in parallel of several units In additional units for connection in parallel of several units For manual control by means of potentiometer (cf. section 5.3) For DigiNet solution Table L5 3: Different configurations of the drive unit Two stages Two separate basic adjustments are possible (e.g. for the two fan speeds). Switching between stage I and is effected by an external command (e.g. with the TempTronic). The current operating stage is indicated with the corresponding lamp. Axial air supply In addition, the position 'Axial air supply' (vane angle = 0 ) can be switched externally. Air supply is vertically downwards, which can be useful e.g. for pre-heating or for night cooling during summer. This operating mode is indicated with the lamp 'Ext.' plus the lamp of the stage that would be set without external command. Summer shifting A special feature of the algorithm is the possibility to reduce the vane angle at high room temperature according to the correction diagram (see diagram L5-1). This is intended for cooling mode, where at high room temperatures in the occupied area higher air velocities are often desired and, with internal heat loads (e.g. machines), also upcurrents 20 C 30 C 40 C Diagram L5 1: Correction diagram counteract the supply air jet. For example, an excess temperature of 7.5 K would result in a reduction of the vane angle by 10. Excess temperature is measured from the intervention point E, which can be set between 20 C and 40 C with the 'E' potentiometer. The shifting is valid for both stages of the VarioTronic. Installation Power supply and connection of the TopVent units must be carried out according to the wiring diagram and all applicable regulations. Installation only requires a connection between the VarioTronic control module and the plug in the Air-Injector. If a separate room air sensor is used (option), connect it to the plug instead of the built-in sensor. Commissioning Commissioning is to be carried out by experts only! Setting the automatic air distributor control is easy and quick with the adjustment diagram (diagram L5-2). Proceed as follows: Balance temperature sensors Under isothermal conditions (i.e. temperature of the supply air sensor = temperature of the room air sensor) adjust the potentiometer 'Just' until the green ISO lamp lights up. (Isothermal conditions appear e.g. about 5 minutes after switching off the unit.) Switch off summer shifting Set the 'E' potentiometer to its maximum position (40 C) to prevent false adjustment by the summer shifting. L 193

196 TopVent Control Systems Type VT-W VT-S Supply voltage AC 230 V ±10 % AC 24 V ±20 % Frequency Hz Hz Control voltage VDC VDC Current consumption 125 ma 125 ma Power 10 VA 3 VA Connection in parallel max. 7 actuators max. 7 actuators Ambient temperature C C Protection rating IP 65 IP 51 Dimensions (W x H x D) 195 x 160 x 130 mm 38 x 76 x 70 mm Setting range ISO Setting range A 0..3 / K Setting range R 1) / K Setting range E C Setting range JUST K 1) In the adjustment diagram only three ranges are specified for slope R; these apply for usual applications. The other setting possibilities ( and ) are valid for special operating conditions. Table L5 5: Setting ranges of VarioTronic Table L5 4: Technical data for VarioTronic L R Actuator for Air-Injector L R Actuator for Air-Injector 24VAC V Supply air sensor 24VAC V Supply air sensor T Y U T Y U Room air sensor Room air sensor T1 T2 S3 N PE L1 Plug T1 T2 S3 N PE L1 Plug 6 x 1.5 mm² 6 x 1.5 mm² L N PE VarioTronic control module A2 A VarioTronic control module 230 VAC Hz max. 10 A 2 x 1.5 mm² Fan speed switching Fig. L5 4: Wiring diagram for VarioTronic wall unit VT-W 1 0 Fixed adjustment 0 = Axial air supply 2 x 1.5 mm² TempTronic 24VAC TempTronic 2 x 1.5 mm² Fan speed switching Fig. L5 5: Wiring diagram for VarioTronic for control panel VT-S 194

197 TopVent Control Systems Set potentiometers With the air flow rate, type size and mounting height read the correct values for your application from the adjustment diagram (diagram L5-2). Set the A, R and ISO potentiometers (in this order) to the correct values. This is necessary for both stages: Left Fan speed I / low air flow rate Right Fan speed / standard air flow rate Set summer shifting Set the intervention point for shifting the control curve between 20 C and 40 C room temperature, as desired. (If this function is not desired, just set the intervention point to a very high value, e.g. 40 C room temperature.) Operation After commissioning the adjustment of the VarioTronic is theoretically correct. It works fully automatically, depending on temperatures and external switching commands. In practice, however, the flow characteristics may be affected e.g. by machinery, thermal influences, etc. Corrections of the adjustment (see table L5-6) must be made under corresponding operating conditions. If, in spite of these corrections, air distribution is still unsatisfactory, please seek Hoval advice. Operating conditions Draughts in the occupied area Table L5 6: Correction possibilities of the VarioTronic setting Air does not reach the occupied are Isothermal Turn ISO to the right Turn ISO to the left Heating Turn A to the left Turn A to the right Cooling Turn R to the right Turn R to the left 1) 1) If the setting of the ISO potentiometers is < 38, in addition, the A potentiometer can be turned to the left. Mounting height H [m] Setting range ISO [ ] Size 9 / Size L Diagram L5 2: Adjustment diagram Setting range A [ / K] Air flow rate [m³ / h] Setting range R [ / K] 195

198 TopVent Control Systems 5.3 Manual air distribution control The following components are used for manual air distribution control: Potentiometer Actuator for Air-Injector The potentiometer is for manual adjustment of the air discharge angle: 0 % Vertical air supply 100 % Horizontal air supply A maximum of 7 Air-Injectors can be controlled in parallel with one potentiometer. Two designs are available: Potentiometer wall unit (PMS-W) Potentiometer for control panel (PMS-S) The actuator adjusts the Air-Injector vanes in a range from 0 (= vertical air supply) to 50 (= horizontal air supply). To ensure the correct vane position even after switch-on, the actuator always performs the following starting cycle (duration about 3 min): Actual position 0 50 Desired position Fig. L5 6: Potentiometer PMS-W Transformer A transformer is available for low voltage supply. It is installed in a plastic casing with two terminal connections (for wall-mounting). A maximum of 7 actuators can be connected to one transformer. Table L5 7: Components for manual air distribution control Type PMS-W PMS-S Control voltage AC 24 V, 50 Hz AC 24 V, 50 Hz Control signal Y DC V DC V Setting range 0 % % 0 % % Connection Terminals 1.5 mm² Terminals 1.5 mm² Dimensions 84 x 84 x 60 mm 48 x 48 mm Table L5 8: Technical data of potentiometer PMS-W (wall unit) and potentiometers PMS-S (for control panel) Control voltage AC 230 / 24 V Usage For indoor use Performance 10 VA Temperature range C Built-in fine-wire fuse 0.5 A Ambient humidity % rh Dimensions 135 x 74 x 72 mm Type Nominal voltage Control signal Operating range Torque Running time 5.2 VT-A AC 24 V, 50 Hz DC V DC V 8 Nm 150 s Table L5 9: Technical data of transformer (TA) Table L5 10: Dimensions and technical data of the actuator (VT-A) 196

199 TopVent Control Systems M Air-Injector L R 24 VAC V Y U Actuator for Air-Injector 3 x 1.5 mm² Terminal strip Control panel Potentiometer Y Z AC 24 V Y = V DC 230 V 24 V 2 x 1.5 mm² 1 N 2 L Transformer Potentiometer AC 230 V 50 Hz Fig. L5 7: Installation diagram for potentiometer PMS-W Fig. L5 8: Wiring diagram for potentiometer PMS-W L 197

200 10 TopVent Control Systems 5.4 Fixed adjustment of air distribution Where air distribution takes place under unchanging operating conditions (nearly constant supply air temperature and air flow rate) it can be permanently set: Read the correct set value for the vane angle from the corresponding adjustment diagram (diagrams L5-3, L5-4). Manually turn one of the vanes so that this value is reached on the driving disk. Fix this position with the wing nut. If required, the wing nut can be loosened and readjusted at any time. t [K] = t Supply air - t Room air Mounting height H [m] Air flow rate [m³/ h] Vane angle [ ] Diagram L5 3: Adjustment diagram for fixed adjustment of the Air-Injector in TopVent units size 6 t [K] = t Supply air - t Room air Mounting height H [m] Air flow rate [m³/ h] Vane angle [ ] Diagram L5 4: Adjustment diagram for fixed adjustment of the Air-Injector in TopVent units size 9 and

201 TopVent Control Systems 6 Fresh air rate control The following components are used for manual control of the fresh air rate: Potentiometer The potentiometer is for manual adjustment of the fresh air / recirculated air mixing ratio: 0 % 0 % Fresh air 100 % 100 % Fresh air A maximum of 7 TopVent units can be controlled in parallel with one potentiometer. Potentiometer wall unit (PMS-W) Potentiometer for control panel (PMS-S) Actuator for mixed air box The actuator adjusts the fresh air and recirculation dampers in a range from 0 (= 0 % fresh air) to 90 (= 100 % fresh air). To ensure the correct damper position even after switch-on, the actuator always performs the following starting cycle (duration about 3 min): Actual position 0 90 Desired position Fig. L6 1: Potentiometer PMS-W Transformer A transformer is available for low voltage supply. It is installed in a plastic casing with two terminal connections (for wall-mounting). A maximum of 7 actuators can be connected to one transformer. Table L6 1: Components for manual control of the fresh air rate L 199

202 TopVent Control Systems Type PMS-W PMS-S Supply voltage AC 24 V, 50 Hz AC 24 V, 50 Hz Control signal Y DC V DC V Setting range 0 % % 0 % % Connection Terminals 1.5 mm² Terminals 1.5 mm² Dimensions 84 x 84 x 60 mm 48 x 48 mm Table L6 2: Technical data of Potentiometer PMS-W (wall unit) and potentiometers PMS-S (for control panel) Supply voltage AC 230 / 24 V Usage For indoor use Performance 10 VA Temperature range C Built-in fine-wire fuse 0.5 A Ambient humidity % rh Dimensions 135 x 74 x 72 mm Type Nominal voltage Control signal Y Operating range Torque Running time 5.2 MLK-A AC 24 V, 50 Hz DC V DC V 8 Nm 150 s Table L6 3: Technical data of transformer (TA) Table L6 4: Dimensions and technical data of the actuator (MLK-A) M Mixed air box L R 24 VAC V Actuator for mixed air box Y U 3 x 1.5 mm² Terminal strip MH / MK Control panel Potentiometer Y Z AC 24 V Y = V DC 230 V 2 x 1.5 mm² V Potentiometer N L Transformer AC 230 V 50 Hz Fig. L6 2: Installation diagram for potentiometer PMS-W Fig. L6 3: Wiring diagram for potentiometer PMS-W 200

203 TopVent Control Systems 7 Basic control Basic control is a low-cost control system for TopVent MH. It meets all requirements of modern recirculation heating, however, automatic control of the fresh air rate is not available. Basic control is recommended if the units are used mainly for recirculation heating in winter, mainly for fresh air supply (100 % fresh air) during working hours in summer. 7.1 Construction Basic control comprises the following components: TempTronic SHK Potentiometer PMS-W Transformer TA (for connecting two or more TopVent MH to one control unit) The individual components are described in detail in the respective sections of this handbook. Their combination allows for the following additional functions: When the fan is off, the mixed air damper is in position 'Recirculation'. In case of frost hazard, the fan switches off and the mixed air damper goes in position 'Recirculation'. Switching of the heating pump is not possible. Due to the changing operating conditions use of the VarioTronic is recommended. Recirculation heating in winter (automatic) Programme the TempTronic as described in the 'TempTronic' section. Set the potentiometer to 0 % fresh air. Partial fresh air operation in winter is possible, however, due to on / off operation and the different fan speeds the fresh air rate is not constant. In addition, if the adjusted fresh air rate is very high draughts or frost hazard may occur. Fresh air operation in summer (automatic) Set the desired fresh air rate with the potentiometer (normally 100 %). Set the TempTronic selector switch for heating / cooling operation to cooling position. Set the operating mode selector switch to 'Auto.' or 'Auto. I'. Adjust the room set value low enough to ensure that it is always lower than the actual room temperature during working hours. This ensures that the units switch on and draw in fresh air when the clock is ON (room set value). Set the increase of the desired room temperature to 12 K, avoiding the units switching on during the night. Fresh air operation in summer (manual) Set the desired fresh air rate with the potentiometer (normally 100 %). Manually switch fresh air operation with the selector switch for operating modes: I (Y) Fresh air operation at low fan speed (low fresh air rate) ( ) Fresh air operation at high fan speed (high fresh air rate) The TopVent units are off. Table L7 1: Operating instructions for basic control L 201

204 TopVent Control Systems 7.2 Installation Power supply and connection of the TopVent units must be carried out according to the wiring diagram and all applicable regulations. Several TopVent MH units can be switched in parallel. Only units working under equal operating conditions (switching times, temperature, etc.) may be linked in a group. The maximum number depends on the unit size: max. 7 TopVent MH-6 max. 6 TopVent MH-9 max. 3 TopVent MH-10 Multiple TopVent MH: Pilot unit TopVent MH VarioTronic Frost stat Terminal box Terminal box Terminal box TempTronic VarioTronic Transformer Potentiometer Fig. L7 1: Wiring diagram of basic control for multiple TopVent MH: first unit 202

205 TopVent Control Systems Multiple TopVent MH: Unit(s) between first and last unit TopVent MH VarioTronic Frost stat Terminal box Terminal box Terminal box Fig. L7 2: Wiring diagram of basic control for multiple TopVent MH: intermediate unit Multiple TopVent MH: Last unit TopVent MH VarioTronic Frost stat Terminal box L Fig. L7 3: Wiring diagram of basic control for multiple TopVent MH: last unit 203

206 TopVent Control Systems Single TopVent MH TopVent MH VarioTronic Frost stat A... Terminal connection by the installer TempTronic VarioTronic Potentiometer Fig. L7 4: Wiring diagram of basic control for single TopVent MH 204

207 1 Operation Servicing Maintenance Disposal 207 Operation M

208 206

209 TopVent Operation 1 Operation 2 Servicing 1.1 Commissioning Commissioning is to be carried out by experts only! An unauthorised start-up can cause damage. Visually check the units for any damage. Check that wiring diagrams have been followed. Set room temperature controller as described in the user manual. Visually check if the fans rotate in the correct direction at both speeds. An arrow on the nozzle shows the correct direction. Rectify possible wiring errors. Measure current consumption and compare with the information on the nameplate. Check function of units and controls by varying set values and operating times. Adjust the Air-Injector (if installed) according to the mounting height and air flow rate (see part L5 'Air distribution control'). Check room air sensor: Is the sensor installed at a typical position? Is the reading affected by local heat gains, solar gains, etc.? 1.2 Operation Unit control can only be undertaken by authorised individuals! Please refer to the user manual of the installed control system. In general, the plant works fully automatically depending on operating times and temperature conditions. The correct function should be checked periodically. Changes in working times must be corrected accordingly in the controller. Free air passage must be ensured; the air jet must be free to spread out unhindered. Any localisation of heat must be avoided. 1.3 Placing out of operation Turn main switch and isolation switch (option) to Off. If frost hazard exists, drain down the installation or protect it with antifreeze. Inspection and cleaning work to be carried out by experts only! Observe accident prevention regulations! Before undertaking servicing work, turn the main switch and the isolation switch (option) to Off and secure! Wait for the fan to stop! Every 2 4 months Inspect air filters (if installed), clean or exchange. Yearly before start of the heating period Check function of the fan. Visual inspection of the unit. Check function of the Air- Injector and whether fan impellers are dirty. If so, clean. Check control system. Every 2 years Visual inspection of the coil and, if necessary, clean. 3 Maintenance Maintenance work to be carried out by trained experts only. This requires special knowledge not contained in this manual. Spare parts must comply with manufacturer's requirements. Use Hoval original spare parts only! If required, please contact our service offices. 4 Disposal When disposing of components of TopVent units, please note the following: Metal parts should be sent for recycling. Plastic parts should be sent for recycling. Electrical and electronic parts should be sent to special refuse sites. M 207

210 208

211 TopVent Handbook for Planning, Installation and Operation Subject to technical alterations. Art.No Doc.No. Hi12bE1 12 / 2004 Hovalwerk AG, Liechtenstein, 2004

212 Experience Over Many Years Guarantees Sound Advice. Hoval the leading manufacturer of decentralised indoor climate systems. Hoval, a group with production plants and sales offices throughout Europe, is a pioneer in heating technology. Today the product range includes not only boilers but also air heaters, plate heat exchangers, thermal wheels, radiant tube heaters, waste incineration plants and steam boilers. Since 1977 Hoval has manufactured ventilation units in the Schaan factory. The resultant experience forms the basis for Hoval application and technical advisory service. Great Britain Hoval Ltd. Northgate, Newark Notts, NG24 1JN tel fax hoval.co.uk Republic of Ireland Masterair Sales Ltd. John F Kennedy Park, Killeen Road Dublin 12 tel fax masterair.ie Art.Nr Hi12bE1 12 / 2004 Vaduz factory (Liechtenstein) Schaan factory (Liechtenstein) Certified quality. The Hoval quality system is tested and certified under ISO This means that optimised procedures are adhered to in development, fabrication and distribution to guarantee Hoval quality. Hovalwerk AG Austrasse 70, FL-9490 Vaduz, Liechtenstein tel , fax hoval.com, Quality International references in 25 countries. Numerous factories and work places in 25 countries have opted for ventilation units from Hoval during the past few years. They all acknowledge the problem-free operation and the large savings in heating energy. References are available upon request. Conservation of Energy Protection of the Environment